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Double Skin Air Handling Units

Screwless Cabinet for low leakage and assured Indoor Air Quality

Users Manual

DOUBLE SKIN AHUs SCREWLESS

First published February 2009


No part of this publication may be reproduced in any
manner whatsoever without permission in writing from the
President, Electro Mechanical Projects,
Blue Star Limited.
While due care has been taken to avoid errors or misinterpretation,
Blue Star Limited is neither liable nor responsible for consequence
of any action taken, on the basis of this publication.
Since ASHRAE standards use the FPS system, FPS nomenclature
is used in some places in this publication for convenient reference.
Published by Blue Star Limited, Airconditioning Projects Division.
For restricted circulation only. Not for sale.

USER'S MANUAL

CONTENTS
Introduction ..................................................................................................................................

Features of Double Skin Horizontal Floor Mounted AHU ...........................................................

Technical Data .............................................................................................................................

Features of Double Skin Vertical Floor Mounted AHU ................................................................ 10


Technical Data ............................................................................................................................. 11
Features of Double Skin Ceiling Suspended AHU ...................................................................... 13
Technical Data ............................................................................................................................. 14
Transportation and Storage ......................................................................................................... 25
Packing List (typical) ................................................................................................................... 27
Double Skin Horizontal AHU Assembly Procedure ..................................................................... 33
Assembly the AHU ....................................................................................................................... 35
Recommended Tools ................................................................................................................... 50
Electrical Information .................................................................................................................. 51
Cooling and Heating Coil Installation .......................................................................................... 52
Condensate Drain Piping ............................................................................................................ 54
Air System ................................................................................................................................... 55
Pre-Start Up ................................................................................................................................. 56
Operation ..................................................................................................................................... 58
Maintenance ................................................................................................................................ 59
Wintering System Components .................................................................................................. 61
Removal or Reinstallation of Components ................................................................................. 62
Installation of Double Skin Vertical AHU ..................................................................................... 64
Installation of Double Skin Ceiling Suspended AHU .................................................................. 65
Troubleshooting ........................................................................................................................... 66
Spare Parts List ........................................................................................................................... 69
Field Feed Back Card .................................................................................................................. 82
Warranty Claim ............................................................................................................................ 84
Blue Star Service Centres .......................................................................................................... 86

DOUBLE SKIN AHUs SCREWLESS

Introduction
Double Skin Air Handling Units with Screwless Cabinet
For assured air quality
Blue Star, Indias largest and preferred airconditioning company has been
providing expert cooling solutions for nearly six decades. It is with this
expertise we bring to you a wide range of air handling units manufactured
at our own world-class factories.
The Double Skin Air Handling Unit, as the name suggests has an outer
casing made of sandwicthed panels, resulting in low noise, sturdy
construction and better thermal insulation. These have been completely
redesigned in Screwless Cabinet construction. Taper Wedges are used
for fixing and locking of the insulated panels with aluminum frame.

Advantages of new Screwless Cabinet construction:

Reliability and Longer Life


Rigid framework comprises an assembly of externally rounded extruded aluminum anodized profiles that
are anticorrosive and fiberglass corner joints that avoid condensation at corners. The panels are pressure
injected with polyurethane foam, using CFC free R-141 b blowing agent. High and uniform PUF density of 38
2 kg/m3 provides better thermal conductivity and sound attenuation properties.

Better Aesthetics
No gaps and level difference at panel joints. Fixing screws are avoided in assembling panels. The colour of
the AHU is texture finish gray.

High Indoor Air Quality


Double skin panel construction allows easy inspection, cleaning and maintenance of the smooth inner surface,
reducing the risk of dirt and bacteria accumulation. There is no erosion of internal insulation material to
contaminate the air stream. Improved Panel frame arrangement by overlapping wedge and special gasket
reduces air leaks into the casing significantly. This maintains the Indoor Air Quality (IAQ) and also provides
the better thermal and acoustic performance.

Low Noise
Usage of double skin casing, imported AMCA certified fans, anti vibration spring isolators, which isolated the
fan from the main structure thus minimizing vibration and results in low operation noise.

Energy Efficiency
The units utilize Blue Star free flow coils (Coil Nomenclature CDW, CDX, YDW, YDX). The Fins of these coils
have a mild ripple, die formed channels to improve heat transfer efficiency and hence are energy efficient.

USER'S MANUAL

Ease of Assembly and Maintenance


New construction leads to faster assembly. The coil is placed on the sliding channel for ease in service and
maintenance.

Reduces Air bypass in Filter Section


New Design of Filter Frame flush with the cabinet minimizes the chance of air
leakage between the filter frame and the casing.

Standard Filter Sizes


The filter sizes are standardized to the internationally recognized standard of four
sizes in all horizontal AHUs. The filters are pleated to provide more filtration area.

Compact Design
Floor Mounted Equipment footprint has been optimized to make the units more compact. Key components
like Cooling Coil, Blower Assembly and Filters are redesigned for compact design and better performance.

DOUBLE SKIN AHUs SCREWLESS

Features
Double Skin Horizontal Air Handling Units Floor Mounted Type
The horizontal floor mounted units are ideal units to handle high air quantity. The composite design sections
offer both sturdy construction and flexible combination of components such as coils, filters, etc to suit specific
applications hence they are widely used in industrial, clean room and large commercial airconditioning. As all
major components are aligned to the base tray, it is maintenance and service friendly.
These Double Skin Horizontal Floor mounted Air Handling Units are available in 37 models with air quantity
varying from 3250 to 60600 CMH.

Standard features of the Units:


a. Casing
Rigid framework, comprising of smooth, rounded extruded aluminium anodized profiles with fibre glass corner
joints.

Double skin sandwiched panels:


- Outer skin: 0.5 mm pre-painted galvanized sheet steel.
- Inner skin: 0.5 mm plain galvanized sheet steel with 180 GSM Zinc Coating.

Panels are 24+1 mm thick, pressure injected with polyurethane foam, using CFC-free R-141b blowing agent.
Uniform PUF density of 38+/- 2 kg/Cu.m provides better thermal insulation (K factor not exceeding
0.02 W/m-C.)

Insulated Panels are fixed on the aluminium frame using overlap design wedges. The design avoids use of
screws for assembly of panels. 3 mm thick gasket is fixed on frame below the panels. The construction leads
to improved air tightness of the cabinet and hence results in better Indoor Air Quality. It also improves the
Thermal and Acoustic Performance.

The AHU base frame is of 14 G GSS and of 80 mm height.

Drain pan is made of 0.8 mm thick, Powder Coated Galvanized Sheet steel. The drain pan is insulated with
5 mm thick closed cell elastomeric Insulation to avoid surface condensation.

USER'S MANUAL

b. Cooling Coils
The Coils are made of Copper tube of thickness 0.36mm and the aluminium fins of thickness 0.12mm.
Free flow fin configuration is formed in plain aluminium fin stock with mild ripples die formed channels provide
excellent heat transfer capability with low air side Pressure drop. Mechanical expansion of copper tubes with
aluminum fins assure good thermal bonding and improve heat transfer. Coils are complete with copper headers
provided with air vent and drain plugs. In and out connections are of mild steel for convenience to connect to
water line at site.
The coils are placed on sliding channels for ease in service and maintenance.
c. Fans
Fans are of double inlet, double width type with forward curved impeller.
The scroll and impeller are made of galvanized steel sheet.
The fans are AMCA certified and are statically and dynamically balanced.
The whole fan assembly is trim-balanced to ISO1940 & AMCA 204 G2.5 Standard.
Belt-Driven Fans are supplied with three phase, 415V, 50Hz, TEFC squirrel cage Hindustan / Spartan
(A batiliboi group of company) make motor with IP55 protection and with Class F insulation.
d. Pre-Filters
The Pre filter is 50 mm deep in box type construction of efficiency 90% down to 10 microns confirming to
EU 3 class of EN779 specification. The filter media is synthetic, non-woven fire retardant type.
Pre-filter is pleated to provide more filtration area. The Pleated air filter incorporates a 100% synthetic thermal
bonded media with an average arresting exceeding 80% by weight. The filter media is bonded to a metal grid
on the air exiting side, Preventing fluttering and maintaining uniformity of the pleats. The filter pack is enclosed
in an aluminium frame.
e. Hinges and Handles
The fan section is provided with an access door for ease in serviceability of fan and
motor. Nylon handles can be operated from both inside and outside the casing and
are user-friendly.
f. View Port and Marine Lamp
View Port is provided on fan door panel which helps to monitor fan and motor status.
Marine lamp provides easy visibility. This needs to be electricity connected at site.
g. Limit Switch
Door limit switch automatically trips the motor when the door is opened and hence stop the blower.
This needs to be connected up in series with no volt coil of the AHU starter.
h. Damper
Every AHU is supplied with a factory fitted GI, powder coated, opposed blade volume control damper
to facilitate air balancing.

2700

2700

2700

2700

2700

2700

2935

2935

2935

2935

DHW4- 445 -C

DHW4- 455 -C

DHW4- 470 -C

DHW4- 490 -C

DHW4- 500 -C

DHW4- 520 -C

DHW4- 540 -C

DHW4- 570 -C

DHW4- 600 -C

2540

DHW4- 340 -C

DHW4- 430 -C

2335

DHW4- 325 -C

2700

2335

DHW4- 300 -C

2635

2335

DHW4- 290 -C

DHW4- 410 -C

2390

DHW4- 265 -C

DHW4- 390 -C

2175

DHW4- 255 -C

2635

2175

DHW4- 240 -C

2635

2175

DHW4- 230 -C

DHW4- 370 -C

2175

DHW4- 220 -C

DHW4- 355 -C

2035

1865

DHW4- 150 -C

2035

2175

DHW4- 135 -C

DHW4- 200 -C

1670

DHW4- 190 -C

1670

DHW4- 110 -C

DHW4- 120 -C

1865

1670

DHW4- 100 -C

2035

1510

DHW4- 080 -C

DHW4- 175 -C

1715

1510

DHW4- 070 -C

DHW4- 160 -C

1510

1370

DHW4- 050 -C

900

3290

3290

2935

2935

3290

3290

3290

3000

2935

2935

2635

2635

2635

2635

2635

2635

2390

2390

2220

2175

2035

2015

2015

2015

2015

1875

1875

1875

1460

1715

1370

1370

1105

1105

1370

1370

mm

mm

DHW4- 035 -C

Width

2575

2465

2510

2510

2130

2130

2130

2150

2210

2210

2205

2150

2150

2150

1890

1815

1890

1890

1890

1815

1815

1815

1815

1575

1495

1475

1495

1495

1515

1200

1200

1200

1170

950

950

885

885

mm

Height

AHU Overall Dimension

Length

DHW4- 040 -C

AHU MODEL

2896

2896

2642

2642

2946

2896

2794

2692

2642

2591

2337

2337

2286

2337

2337

2337

2083

1981

1829

1829

1727

1676

1575

1727

1727

1575

1473

1422

1168

1422

1372

1168

1067

1067

813

711

559

mm

Fin
Length

2286

2159

2223

2159

1842

1842

1842

1842

1842

1842

1905

1842

1778

1651

1588

1524

1588

1588

1588

1524

1524

1524

1524

1270

1207

1207

1207

1143

1270

953

889

953

889

699

699

635

635

mm

Fin
High

6.62

6.25

5.87

5.70

5.43

5.33

5.15

4.96

4.86

4.77

4.45

4.30

4.06

3.86

3.71

3.56

3.31

3.15

2.90

2.79

2.63

2.55

2.40

2.19

2.08

1.90

1.78

1.63

1.48

1.35

1.22

1.11

0.95

0.75

0.57

0.45

0.35

Sq.m.

Coil
Area

35625

33646

31597

30694

29400

28698

27650

26684

26181

25300

23958

23160

21875

20800

19965

19167

17795

16927

15625

15000

14167

13750

12904

11806

11200

10226

9566

8825

7986

7292

6470

5990

4861

4010

3056

2431

1910

CFM

60563

57198

53715

52180

49980

48787

47005

45363

44508

43010

40729

39372

37188

35360

33941

32584

30252

28776

26563

25500

24084

23375

21937

20070

19040

17384

16262

15003

13576

12396

10999

10183

8264

6817

5195

4133

3247

CMH

Air Qty

Standard Coil Size

FDA 1000 TM

FDA 1000 TM

FDA 1000 TM

FDA 1000 TM

FDA 900 TM

FDA 900 TM

FDA 900 TM

FDA 900 TM

FDA 900 TM

FDA 900 TM

FDA 900 TM

FDA 800 TM

FDA 800 TM

FDA 800 TM

FDA 800 TM

FDA 710 CM

FDA 710 CM

FDA 710 CM

FDA 710 CM

FDA 630 CM

FDA 630 CM

FDA 630 CM

FDA 630 CM

FDA 560 CM

FDA 560 CM

FDA 560 CM

FDA 500 CM

FDA 500 CM

FDA 500 CM

FDA 450 CM

FDA 450 CM

KAT18 X 18CM

KAT18 X 13CM

KAT15 X 15CM

KAT12 X 12CM

KAT12 X 9CM

KAT10 X 10CM

Kruger

1266 * 1266

1266 * 1266

1266 * 1266

1266 * 1266

1130 * 1130

1130 * 1130

1130 * 1130

1130 * 1130

1130 * 1130

1130 * 1130

1130 * 1130

1006 * 1006

1006 * 1006

1006 * 1006

1006 * 1006

898 * 898

898 * 898

898 * 898

898 * 898

800 * 800

800 * 800

800 * 800

800 * 800

714 * 714

714 * 714

714 * 714

638 * 638

638 * 638

638 * 638

568 * 568

568 * 568

557 * 478

430 * 478

471 * 404

395 * 341

309 * 341

331 * 289

W - mm X
H - mm

Fan
Opening

Fan & Motor Details


Fan Model

Double Skin Floor Mounted Horizontal Draw Through Units


40mm TSP

10.49

9.91

9.31

9.04

10.87

10.61

10.22

9.87

9.68

9.35

8.86

10.81

10.21

9.7

9.31

11.23

10.42

9.92

9.15

11.07

10.45

10.14

9.55

10.93

10.37

9.47

11.1

10.24

9.26

10.67

9.47

10.62

11.17

9.95

10.71

10.89

9.43

m/sec.

65.9%

66.1%

65.8%

65.5%

63.3%

63.7%

64.3%

64.7%

64.9%

64.9%

64.5%

63.3%

63.7%

64.6%

64.9%

66.0%

67.0%

67.4%

68.0%

63.2%

63.7%

63.8%

63.9%

66.3%

67.0%

67.5%

62.7%

63.4%

63.8%

64.3%

64.6%

67.3%

68.6%

64.7%

62.0%

63.4%

63.3%

15

15

11

11

11

11

11

11

11

11

11

11

9.3

7.5

7.5

7.5

7.5

7.5

5.5

7.5

5.5

5.5

5.5

5.5

5.5

5.5

5.5

3.7

3.7

3.7

3.7

2.2

2.2

1.5

1.5

1.1

0.75

kW

65.9%

65.2%

63.9%

63.1%

64.8%

64.9%

64.8%

64.4%

64.0%

63.2%

61.8%

64.7%

64.9%

64.7%

64.4%

67.3%

67.9%

68.2%

67.4%

63.9%

64.0%

64.0%

64.0%

67.4%

67.4%

66.2%

63.5%

63.8%

63.3%

64.7%

62.9%

65.8%

69.2%

63.8%

60.9%

64.5%

61.0%

18.5

15

15

15

15

15

15

15

15

15

11

11

11

11

11

9.3

7.5

7.5

7.5

7.5

7.5

7.5

7.5

5.5

5.5

5.5

5.5

5.5

5.5

3.7

3.7

3.7

2.2

2.2

1.5

1.5

1.1

kW

Motor
Power

50 mm TSP

Fan Outlet
Fan
Motor
Fan
Velocity Effieiency Power Efficiency

1550

1525

1500

1465

1425

1400

1380

1365

1340

1325

1300

1200

1180

1160

1140

1060

850

840

750

735

715

705

675

615

590

560

505

475

450

435

425

415

350

340

245

235

200

Kg.

With 4 RD
Coil

1685

1650

1625

1590

1565

1540

1525

1500

1480

1465

1440

1325

1300

1285

1265

1150

940

925

825

800

785

775

735

655

640

615

555

525

500

470

460

445

375

365

260

250

215

Kg.

With 6 RD
Coil

Operating Wt. (Approx)

DOUBLE SKIN AHUs SCREWLESS

Technical Specifications

DHW4 - 035-C
DHW4 - 040-C
DHW4 - 050-C
DHW4 - 070-C
DHW4 - 080-C
DHW4 - 100-C
DHW4 - 110-C
DHW4 - 120-C
DHW4 - 135-C
DHW4 - 150-C
DHW4 - 160-C
DHW4 - 175-C
DHW4 - 190-C
DHW4 - 200-C
DHW4 - 220-C
DHW4 - 230-C
DHW4 - 240-C
DHW4 - 255-C
DHW4 - 265-C
DHW4 - 290 -C
DHW4 - 300-C
DHW4 - 325-C
DHW4 - 340-C
DHW4 - 355-C
DHW4 - 370-C
DHW4 - 390-C
DHW4 - 410-C
DHW4- 430-C
DHW4- 445-C
DHW4- 455-C
DHW4- 470-C
DHW4- 490-C
DHW4- 500-C
DHW4- 520-C
DHW4- 540-C
DHW4- 570-C
DHW4- 600-C

AHU MODEL

1910
2431
3056
4010
4861
5990
6470
7292
7986
8825
9566
10226
11200
11806
12940
13750
14167
15000
15625
16927
17795
19167
19965
20800
21875
23160
23958
25300
26181
26684
27650
28698
29400
30694
31597
33646
35625

CFM
3247
4133
5195
6817
8264
10183
10999
12396
13576
15003
16262
17384
19040
20070
21998
23375
24084
25500
26563
28776
30252
32584
33941
35360
37188
39372
40729
43010
44508
45363
47005
48787
49980
52180
53715
57198
60563

CMH

Air Qty

22
28
32
42
42
46
54
56
46
56
58
62
68
68
62
66
68
72
72
78
82
92
92
92
90
92
92
102
104
106
110
114
116
104
104
114
114

Inch

Fin

20
20
22
22
28
30
28
30
40
36
38
38
38
40
48
48
48
48
26+24
26+24
26+24
48
26+24
26+26
28+28
30+28
30+30
30+28
30+28
30+28
30+28
30+28
30+28
34+34
36+34
34+34
36+36

3.82
4.86
6.11
8.02
10.21
11.98
13.13
14.58
15.97
17.50
19.13
20.45
22.43
23.61
25.83
27.50
28.33
30.00
31.25
33.85
35.59
38.33
39.93
41.53
43.75
46.32
47.92
51.35
52.36
53.37
55.38
57.40
58.40
61.39
63.19
67.29
71.25

Sq.Ft.

Tube High Coil Area


Length

2
2
2
2
2
2
2
2
2
2
2

2
2
2
2
2
2
2

1
1
1
1

1
1
1/4
1/2
1/2
1/2
2
2
2
2
2
2
2
2
2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
2
2
2
2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2

Inch1

Coil In/Out
Size

Standard Coil Size

D
D
D
D
D
D
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B

4 Row
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C

6 Row

Coil Circuit

1
1
1
2
2
2
2
2
4
4
4
4
6
6
6
6
6
6
6
6
6
8
8
12
12
12
12
12
12
12
15
15
15
12
12
15
15
4
4
5
5

3
3
3
3
3
3
3
4
4

2
2
2
2

610 X 305
Qty

3
3

3
3

2
2

2
2
2

1
1

1
1

305 X 610

Filter sizes in mm (W X H)
610 X 610

Double Skin Floor Mounted Horizontal Draw Through Units

1
1

1
1

1
1

305 X 305

USER'S MANUAL

DOUBLE SKIN AHUs SCREWLESS

Features
Vertical Double Skin Air Handling Units
Vertical Air Handling Units are designed to occupy lesser floor space than the horizontal units. These units are
preferred when floor space is a constraint. They are available in 10 models with airflow ranging from 3500 CMH
to 30280 CMH and an external static pressure at 12 mm and 20 mm. These are predominantly used for applications
where multiple units are required to aircondition a floor constrained by ceiling heights; duct sizing,
floor space etc.

10

730

780

830

980

830

980

980

1041

1132

1132

DVW-4-050

DVW-4-070

DVW-4-100

DVW-4-140

DVW-4-170

DVW-4-200

DVW-4-250

DVW-4-270

DVW-4-300

mm

3466

3164

2932

2932

2728

2220

1763

1591

1388

1032

mm

2372

2372

2244

2009

2009

1892

1852

1525

1349

1283

mm

LENGTH WIDTH HEIGHT

DVW-4-035

AHU
MODEL

3048

2794

2642

2642

2438

1930

1473

1321

1118

762

mm

FL

1080

1080

1016

826

762

762

762

572

508

508

mm

FH

Coil Details

3.29

3.02

2.68

2.18

1.86

1.47

1.12

0.75

0.57

0.39

Sq.m

Coil
Area

Floor Mounted Vertical Double Skin Air Handling Unit

17708

16233

14444

11736

10000

7917

6042

4063

3056

2083

CFM

30104

27595

24556

19951

17000

13458

10271

6906

5194

3542

CMH

Air Qty.

557*478 - 1#

471*404 - 1#

395*341 - 1#

331*289 - 1#

H-mm

W-mm X

Fan

FDA 500C2M

FDA 500C2M

FDA 450C2M

KAT 18/18S2L

638*638 - 2#

638*638 - 2#

568*568 - 2 #

557*478 - 2#

KAT 18/13S2L 430*478 - 2 #

KAT 15/15S2L 471*404 - 2 #

KAT 18/18SL

KAT 15/15SL

KAT 12/12SL

KAT 10/10SL

Dia. in

Fan Model
Opening
Velocity

10.27

9.42

10.57

10.41

11.49

9.82

10.72

10.08

10.71

10.28

M/Sec

Fan
Outlet

7.5

5.5

5.5

5.5

3.7

3.7

2.2

1.5

1.1

0.75

ESP

7.5

7.5

7.5

5.5

5.5

3.7

3.7

2.2

1.5

1.1

ESP

12 mm 20 mm

Motor kW

850

750

670

590

560

470

395

330

225

190

Kg.

950

815

745

650

610

520

435

360

245

205

Kg.

With 4 RD With 6 RD
Coil
Coil

Operating Wt.
(Approx.)

USER'S MANUAL

11

12

110
120

DVW - 4 - 300 17708 30080

600

W
600

H
400

W
400

H
600

W
500

H
500

W
500

10

DVW - 270

DVW - 300

DVW - 200

DVW - 250

DVW - 170

500

600

DVW - 140

600

2 1/2

2 1/2

2 1/2

1 1/2

1 1/4

1 1/4

Inch

SIZE

DVW - 100

DVW - 070

DVW - 050

DVW - 035

500

600

2 5/8

2 5/8

2 5/8

2 1/8

2 1/8

2 1/8

1 5/8

1 3/8

1 3/8

1 1/8

Inch

35.42 CDW-12-A-4-H-B-34-L/R-120-L

32.47 CDW-12-A-4-H-B-34-L/R-110-L

28.89 CDW-12-A-4-H-B-32-L/R-104-L

MS

6 Rows Deep

SIZE

COIL NOMENCLATURE

400

W
400
2

H
500

35.5

32.3

29.1

23.3

20.7

17.2

12.9

9.0

6.5

4.3

FT

Area

FILTER

CDW-12-A-6-H-B-34-L/R-120-L

CDW-12-A-6-H-B-34-L/R-110-L

CDW-12-A-6-H-B-32-L/R-104-L

CDW-12-A-6-H-B-26-L/R-104-L

CDW-12-A-6-H-B-24-L/R-96-L

CDW-12-A-6-H-C-24-L/R-76-L

CDW-12-A-6-H-C-24-L/R-58-L

CDW-12-A-6-H-C-18-L/R-52-L

CDW-12-A-6-H-C-16-L/R-44-L

CDW-12-A-6-H-D-16-L/R-30-L

HEADER CONNECTOR

MODEL

CDW-12-A-4-H-B-24-L/R-96-L

CDW-12-A-4-H-C-24-L/R-76-L

CDW-12-A-4-H-C-24-L/R-58-L

CDW-12-A-4-H-C-18-L/R-52-L

CDW-12-A-4-H-D-16-L/R-44-L

CDW-12-A-4-H-D-16-L/R-30-L

23.47 CDW-12-A-4-H-B-26-L/R-104-L

20.00

15.83

12.08

8.13

6.11

4.17

4 Rows Deep

COIL NOMENCLATURE

COPPER

FLAT FILTER SIZE (48mm THK.)

34

34

32

26

24

24

24

18

16

16

FT

AREA

COIL

AHU

Frontal Flat Filter Sizes

104

DVW - 4 - 270 16233 27574

76

58

13448

10263

DVW - 4 - 250 14444 24536

7917

DVW - 4 - 140

52

44

96

6042

DVW - 4 - 100

6901

5190

104

4063

DVW - 4 - 070

30

Inch

High

Length

DVW - 4 - 200 11736 19936

3056

DVW - 4 - 050

3539

CMH

Tube

Fin

DVW - 4 - 170 10000 16987

2083

CFM

AIR QTY.

DVW - 4 - 035

AHU MODEL

Coil Details

Vertical Double Skin Air Handling Unit

2 5/8

2 5/8

2 5/8

2 1/8

2 1/8

2 1/8

1 5/8

1 3/8

1 3/8

1 1/8

Inch

SIZE

HEADER

COPPER

2 1/2

2 1/2

2 1/2

1 1/2

1 1/4

1 1/4

Inch

SIZE

CONNECTOR

MS

DOUBLE SKIN AHUs SCREWLESS

USER'S MANUAL

Features
Ceiling Suspended Units
These units as the name suggests should be suspended from the ceiling thus requiring no floor space. These
units are ideal for commercial application where floor space is at a premium. As they are compact and can be
tucked away above the false ceiling, they find a place inside the conditioned area itself. Thereby reducing installation
costs and also remains unobtrusive giving flexibility to the design of the interior. Panels are fixed to the framework
by wedges thus avoiding usage of screws. They are available in 18 models with air quantity ranging from 1770
CMH to 13568 CMH and an external static pressure range of 12 mm and 20 mm.
The three models DCWSL-035,DCWSL-050 & DCWSL-070 are available in both direct driven with 3 speed single
phase motor or belt driven with 3 phase motor and the other AHUs are available in belt driven models only.

13

14

556

556

556

662

662

810

810

810

810

810

810

1238

1238

1743

1743

DCW4SL-027-B 908

DCW4SL-035-B 908

DCW4SL-042-B 948

DCW4SL-050-B 948

DCW4SL-060-B 1048 2200

DCW4SL-070-B 1048 2200

DCW4SL-078-B 1048 2130

DCW4SL-085-B 1048 2130

DCW4SL-093-B 1099 2097

DCW4SL-100-B 1099 2097

DCW4SL-110-B 1149 2333

DCW4SL-118-B 1149 2333

DCW4SL-127-B 1149 2638

DCW4SL-135-B 1149 2638

mm

556

556

556

556

mm

784

mm

DCW4SL-017-B 908

AHU Model

AHU Overall
Dimensions

(b) Belt Driven Type

2337

2184

2032

1880

1727

1778

1829

1676

1930

1727

1473

1219

965

762

508

mm

FL

0.735

0.561

0.368

Sq. Mt

Coil
Area

3958

3021

1979

CFM

635

635

635

635

635

572

508

508

381

381

381

381

381

381

381

mm

FH

1.484

1.367

1.290

1.194

1.097

1.016

0.929

0.852

0.735

0.658

0.561

0.465

0.368

0.290

0.194

Sq. Mt

Coil
Area

7986

7465

6944

6424

5903

5469

5000

4583

3958

3542

3021

2500

1979

1563

1042

CFM

13568

12683

11798

10913

10035

9297

8500

7791

6729

6021

5135

4250

3362

2655

1770

CMH

Air Quantity

6729

5135

3365

CMH

Air Quantity

Standard Coil Size

1930 381

DCW4SL-070-D 1048 2200 556

381

965

1473 381

mm

FH

DCW4SL-050-D 948 1743 556

mm

mm

mm mm

FL

Standard Coil Size

DCW4SL-035-D 908 1238 556

AHU Model

AHU Overall
Dimensions
(Fan, Coil,
Prefilter)

(a) Direct Driven Type

Fan Model

395 * 341 2 #

395 * 341 2 #

309 * 521 2 #

309 * 521 2 #

331 * 289 2 #

265 * 289 2 #

265 * 289 2 #

232 * 262 2 #

331 * 289 - 1#

265 * 289 - 1#

232 * 262 - 1#

W-mm * H-mm

Fan Opening

KAT 15-15 S2L 471 * 404 2 #

KAT 15-15 S2L 471 * 404 2 #

KAT 15-11 S2L 373 * 404 2 #

KAT 15-11 S2L 373 * 404 2 #

KAT12-12 S2L

KAT12-12 S2L

KAT12-9 S2L

KAT12-9 S2L

KAT10-10 S2L

KAT10-8 S2L

KAT10-8 S2L

KAT 9 - 7 S2L

KAT10-10 SL

KAT10-8 SL

KAT 9 - 7 SL

Kruger

331 * 289 - 1#

265 * 289 - 1#

331 * 289 - 1#

W-mm * H-mm

Fan Opening

Fan & Motor Details

KDD10-10 S2L

KDD10-08 S2L

KDD10-10 SL

Kruger

Fan Model

9.91

9.26

10.88

10.06

10.35

9.59

11.20

10.27

9.77

10.92

9.31

9.71

9.77

9.64

8.09

m/s

Fan
Outlet
Velocity

9.77

9.31

9.77

m/s

3.7

3.7

3.7

2.2

2.2

2.2

2.2

2.2

1.5

1.5

1.1

1.1

0.75

0.55

0.55

kW

Motor
Power

3.7

3.7

3.7

3.7

3.7

3.7

2.2

2.2

2.2

1.5

1.5

1.1

1.1

0.75

0.55

kW

Motor
Power

20mm
ESP

0.55

0.55

0.55

Motor Kw.

12 mm ESP

12mm
ESP

Fan Outlet
Velocity

Fan & Motor Details

Size

610 * 610

610 * 610

610 * 610

3
1

610 * 610
305 * 610

305 * 610

610 * 610

610 * 610

1
3

500 * 500

500 * 500
400 * 500

Qty

400 * 500

500 * 400

500 * 400

500 * 400

500 * 400

500 * 400

500 * 400

600 * 400

-mm * H-mm

Size

Pre Filter
(50mm thick.)

500 * 400

500 * 400

500 * 400

Operating Wt.
(Approx.)

290

195

165

Kg.

310

215

180

Kg.

With 4 RD With 4 RD
Coil
Coil

Operating Wt.

450

440

425

415

395

385

360

345

330

320

225

215

190

175

150

Kg.

49 5

475

460

445

435

425

400

380

360

348

245

230

205

195

170

Kg.

With 4 RD With 4 RD
Coil
Coil

Qty

Pre Filter
(50mm thick.)

W-mm * H-mm

Double Skin Ceiling Suspended AHU-Technical Specification

DOUBLE SKIN AHUs SCREWLESS

1042

1563

1979

2500

3021

3542

3958

4583

5000

5469

5903

6424

6944

7465

7986

DCW-027

DCW-035

DCW-042

DCW-050

DCW-060

DCW-070

DCW-078

DCW-085

DCW-093

DCW-100

DCW-110

DCW-118

DCW-127

DCW-135

CFM

13576

12691

11805

10921

10035

9297

8500

7791

6729

6021

5136

4250

3364

2657

1771

CMH

Air Qty

DCW-017

AHU Model

92

86

80

74

68

70

72

66

76

68

58

48

38

30

20

Inch

Fin
Length

20

20

20

20

20

18

16

16

12

12

12

12

12

12

12

Tube
High

50.17

47.22

44.27

41.32

38.37

35.42

32.47

28.89

23.47

20.00

15.83

12.08

8.13

6.11

4.17

FT

Coil
Area

CDW-12-A-4-H-B-20-L/R-92-L

CDW-12-A-4-H-B-20-L/R-86-L

CDW-12-A-4-H-B-20-L/R-80-L

CDW-12-A-4-H-B-20-L/R-74-L

CDW-12-A-4-H-B-20-L/R-68-L

CDW-12-A-4-H-B-18-L/R-70-L

CDW-12-A-4-H-B-16-L/R-72-L

CDW-12-A-4-H-B-16-L/R-66-L

CDW-12-A-4-H-B-12-L/R-76-L

CDW-12-A-4-H-B-12-L/R-68-L

CDW-12-A-4-H-C-12-L/R-58-L

CDW-12-A-4-H-C-12-L/R-48-L

CDW-12-A-4-H-D-12-L/R-38-L

CDW-12-A-4-H-D-12-L/R-30-L

CDW-12-A-4-H-D-12-L/R-20-L

4 Rows Deep

Coil Nomenclature

2 1/8

2 1/8

2 1/8

2 1/8

1 5/8

1 5/8

1 5/8

1 5/8

1 3/8

1 3/8

1 1/8

1 1/8

1 1/8

1 1/8

1 1/8

Inch

Copper
Header
Size

1 1/2

1 1/2

1 1/2

1 1/2

1 1/4

1 1/4

Inch

MS
Connector
Size

Double Skin Ceiling Suspended AHU - Coil Details

CDW-12-A-6-H-B-20-L/R-92-L

CDW-12-A-6-H-B-20-L/R-86-L

CDW-12-A-6-H -B-20-L/R-80-L

CDW-12-A-6C-H-B-20-L/R-74-L

CDW-12-CA-6-H-B-20-L/R-68-L

CDW-1 2-A-6-H-B-18-L/R-70-L

CDW-12-A-6-H-B-16-L/R-72-L

CDW-12-A-6-H-B-16-L/R-66-L

CDW-12-A-6-H-B-12-L/R-76-L

CDW-12-A-6-H-B-12-L/R-68-L

CDW-12-A-6-H-C-12-L/R-58-L

CDW-12-A-6-H-C-12-L/R-48-L

CDW-12-A-6-H-D-12-L/R-38-L

CDW-12-A-6-H-D-12-L/R-30-L

CDW-12-A-6-H-D-12-L/R-20-L

6 Rows Deep

Coil Nomenclature

2 1/8

2 1/8

2 1/8

2 1/8

1 5/8

1 5/8

1 5/8

1 5/8

1 5/8

1 5/8

1 1/8

1 1/8

1 1/8

1 1/8

1 1/8

Inch

Copper
Header
Size

1 1/2

1 1/2

1 1/2

1 1/2

1 1/2

1 1/2

Inch

MS
Conenctor
Size

USER'S MANUAL

15

DOUBLE SKIN AHUs SCREWLESS

CDW / CDX Coils: Nomenclature


1. CDW Water Cooling Coils:
CDW

12

24

94

Comfort Water Cooling Coil


Fins per Inch, 12 FPI
Fins Material, A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H: Horizontal
Circuiting (Tubes per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand, R: Right, L: Left
Finned Length (FL), 26 to 114
L: Loose

Note: Field to specify (a) Circuit type: B. C. D; (b) Hand-off connection: LHS, RHS.
Coil Specifications: OD Copper tube, Tube thinkness 0.36mm, Fin thickness: 0.12mm Aluminium fins.

16

USER'S MANUAL

2. CDX Direct Expansion Cooling Coils:

CDX

12

24

94

0156

40

12

Comfort Direct Exp.


Fins per Inch, 12 FPI
Fins Material A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H: Horizontal
Circuiting (Tuber per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand. R: Right, L: Left
Finned Length (FL), 26" to 114"
L: Loose
Total Coil Load in MBH,
1 MBH = 1000 BTU/HR
Suction Temp., Deg. F
Tubes per Circuit, B=4, C=6, D=8
No. of Circuits

Note: Field to specify (a) Circuit type: B. C. D; (b) Hand-off connection: LHS, RHS.
Coil Specifications: OD Copper tube, Tube thinkness: 0.36mm, Fin thickness: 0.12mm Aluminium fins.

17

DOUBLE SKIN AHUs SCREWLESS

Double Skin Horizontal Floor Mounted ('E' Family)


Design:
Computerised selection
AHU selection software is used for optimal model selection for customised needs. The selection software provides
the following information:

Overall dimensional details

Technical Data Sheet

Sections selected

GA Drawing

Details of Individual sections

Costing Sheet

Casing
Rigid framework, comprising of externally chamfered extruded aluminum anodised profiles, with fibre glass corner
joints.

Double skin sandwiched panels :


Inner Skin

: 0.5mm plain galvanized sheet confirming to IS 277.

Sheet options

: 0.6mm GP, 0.8mm GP, 1.0mm GP, 1.2mm GP, 0.9AI, 1.2mm Al,
0.6mm SS(304), 0.8mm SS(304).

Outer Skin

: 0.5mm pre-painted galvanised sheet.

Sheet options

: 0.6mm PP, 0.8mm PP, 1.0mm PP, 0.9mm AI, 1.2mm Al, 0.6mm SS-304,
0.8mm SS-304.

Panels are pressure injected with polyurethane foam, using CFC-free R-141b blowing agent. High and uniform
PUF density of 38+ 2Kg/m3 provide better thermal insulation K factor (not exceeding 0.02 Watt / MC) and
sound attenuation properties. The following options can be selected based on customer requirement.

Option 1: Panels of 24+ 1mm thickness with standard aluminum extrusions and fiberglass corner joints.

Option 2: Panels of 46+ 1mm thickness with internally coved thermal break aluminum extrusions and
fiberglass corner joints. Recommended for total static pressure above 85 mm and these AHUs are suitable
for outdoor installation.

Panels are fixed to frame with tapered wedges inserted in aluminum extrusions. The gaskets have stable
thermal conductivity and less water vapour permeability.

Fan and motor are mounted on aluminium extruded slide rail base frame. It is isolated from main casing by
using vibration isolators (using 15mm nominal deflection). To arrest vibration, fan outlet is connected to the
AHU casing using fire and moisture resistant canvas.

Hinged service door in fan section provides easy access to fan and motor. View port is provided on fan door
panel to help to monitor fan and motor status. Marine lamp provides easy visibility. Door limit switch
automatically trips the motor when the door is opened and hence stop the blower.

Drain pan with differential slope assures quick and complete water drainage ensuring high Indoor Air Quality
(IAQ). Drain Pan is 80mm deep and fabricated from 0.8 mm thick GI Powder Coated and optional 1.25mm
powder coated or corrosion resistant SS-304 stainless steel is available. The drain pan is insulated for thermal
protection with 5mm thick closed cell elastomeric insulation to avoid surface condensation.

AHUs with stack coils have additional intermediate G.I powder coated / stainless steel drain pan to collect
the condensate of top coil and drain through PVC drop tubes to the main drain pan without flooding the lower
coil.

18

USER'S MANUAL

AHU is supplied with factory fitted GI, powder coated, opposed blade volume control damper to facilitate
field balancing.

Aluminium die cast powder coated hinges provide adequate strength to the door. Nylon handles can be
operated from both inside and outside the casing and are user friendly.

Cooling Coils
Free flow fin configuration formed by mild ripples and die formed channels provide excellent heat transfer
capability with low air pressure drop. Mechanical expansion of copper tube with aluminium fins assures tight
bonding, providing optimum heat transfer. Coils are complete with copper headers.
Water or Direct Expansion coils can be selected based on requirement. Water coils are self draining and vented
type. Design working pressure is 250 psig. at 300F.
The following options of sectional length can be selected based on requirement:

Coil Section up to 6 Row Deep

Coil Section up to 8 Row Deep

Cooling Coil 6 Row Deep and Heating Coil 2 Row Deep

Cooling Coil 8 Row Deep and Heating Coil 2 Row Deep

Fans
Fans are imported, AMCA certified, energy efficient, with double inlet, double width, forward or backward curved
impeller. All wheels are statically and dynamically balanced. Fan bearings are self-aligning, pillow block or flanged
type regreasable ball bearings. The scroll and impeller are made of galvanised steel sheet. The fan is V-belt
driven through a 3 phase, 415V6%, 50 Hz AC, squirrel cage, TEFC induction, 4 Pole, IP55, Class F motor.
AHUs with static pressure requirement of more than 85mm are suggested with backward curved impeller.

Pre Filters (50mm thick)


Pre Filters are pleated to provide more filtration area. The filters are of the cassette type. The filter media are of
the synthetic non-woven type, supported with aluminium and HDPE mesh and generally conforming to EU-3 of
EN-779 specifications. Filter efficiency is 90% down to 10 micron. Filters are provided with handles for easy
removal.

Mixing Box / Inlet Section (Optional)


Section is designed for interconnecting return air and fresh air. The following options can be selected based on
requirement:

Mixing Box section with one Return Air Damper and Pre Filters

Mixing Box section with one Fresh Air Damper & Pre Filters.

Mixing Box section with Return and Fresh Air Damper and Pre Filters

Mixing sections are fitted with parallel or opposed blade multi-leaf dampers suitable for manual or motorised
operations. Select aluminium damper only for requirement with motorised modulating motor operation.

19

DOUBLE SKIN AHUs SCREWLESS

Fine / Bag Filter Section (Optional)


Section is designed for 300/500/600mm deep Fine filters or Bag filter with 25 mm flange.
The filters are arranged vertically in the specially designed heavy-duty galvanized sheet steel frame to avoid air
bypass and are removable from front. Filters are mounted on frame with positive clamping arrangement. Filter
section is provided with access door panel, with aluminum die-cast powder coated heavy duty hinges and nylon
handles with positive locking. The handle can be operated from both ends for ease in serviceability.

HEPA Filter Section (Optional)


Section is designed for 300mm deep HEPA Filters with 25 mm flange.
The filters are arranged vertically in the specially designed heavy-duty galvanised sheet steel frame to avoid air
bypass and are removable from front. Filters are mounted on frame with positive clamping arrangement. HEPA
Filter section is provided with access door panel, with aluminum die-cast powder coated heavy duty hinges and
nylon handles with positive locking. The handle can be operated from both ends for ease in serviceability. HEPA
Filter should be selected only after Fine or Bag filters.

Combination Filter Section (Optional)


Section is designed for combination of 50mm thick Pre Filters mounted together with Fine / Bag Filters. The filters
are arranged vertically in the heavy duty galvanised sheet steel frame and removable from front. Filters are
mounted on frame with positive clamping arrangement. Fine / Bag filters can be removed only after the removal
of prefilter. All filters are also available in Aluminium flange for phama or clean room application.

Face and Bypass Damper Section (Optional)


Standard face and bypass dampers are of opposed blade type. Face damper is at the bottom in front of the coil,
and bypass damper is on the top. Two dampers are interlocked and provide a single control point. The opening
size in the frame for mounting the Face damper will be equal to maximum size of coil
Select aluminium damper only for requirement with motorised operation with modulating motor. Motorised
actuators are of direct mounting type. It could be two position (on/off) or modulating (input signal 0-10V DC or
4-20mA).

Droplet Eliminator Section (Optional)


To avoid condensate or spray of water carryover into the fan section, suggest use the following droplet eliminator
after the coil or spray section:
2 Pass GI / PVC Droplet Eliminator
4 Pass GI / PVC Droplet Eliminator

Humidification Section (Optional)


Celdek type humidification section is provided in AHU for cooling and humidification purpose, this is required in
places where the temperature is quite high with low humidity.
In humidification section 175 mm high sump is used to store the water and this water is circulated and spread
over the cellulose Pad (Celdek Pad) with the help of Pump and piping arrangement.
The cellulose pad is designed at 500 FPM (2.54m/sec) of Air velocity and it is available in 6" (150 mm),
8" (200 mm) of thickness.
20

USER'S MANUAL

8" Cellulose pad should be used to get the saturation efficiency of about 90%.
The droplet eliminator of 4 pass must be provided after the humidification section to avoid any water carry over
in the supply air.

Heater Section
Heater section with appropriate capacity of heater should be selected to maintain the RH.
These heaters can be provided in number of stages and banks as per the requirement.

Heat Recovery Wheel


Heat Recovery wheel is used in applications where we want to utilize the heating or cooling of the supply air
without mixing with the fresh air.
In other words heat recovery wheels are desirable where we want the heat transfer from supply air to the fresh air
without the mass transfer.
It is used in fresh air application in double tier arrangement.
Heat recovery wheel is placed before the coil and as it recover some quantity of heat (Cooling) from the supply
air, it helps reducing the load on the coil and hence lesser capacity of chiller/condensing unit is required.
The effectiveness of the heat recovery wheel is about 75 80%.

Heat Pipe
Run around type (Horse shoe type) or vertical heat pipe can be provided in our AHUs.
Run around type Heat Pipe has Pre cooling and Re Heating coils, connected through the refrigerant piping.
The hot air interact with the Pre cooling side of the coil and get cooled, the refrigerant inside the coil get evaporated
and get accommodated in the reheating coil.
This pre cooling helps in reducing the load on the main coil and the air after passing through the main coil gets
further cooled and is with high RH.
The Re heating side of the coil exchanges the heat with this cooled and high RH Air, and gets converted into
liquid form.
This liquid state refrigerant due to gravity gets accumulated in the pre cooling coil.
The Air After passing through the Re-Heating Coil gets heated to maintain the desirable temp. 22-24C in the
room with a moderate RH of 50-60% in the room, which is desirable.
The effectiveness of the heat Pipe is about 45 65 %.
The vertical type of heat pipe is used in two tier arrangement, which recovers the sensible heat from return air.

Variable Pitch pulley


Variable Pitch Pulley can be provided in AHUs, which can be set as per the Air Quantity requirement.

Flat belt
Flat belt with pulley arrangement cab be provided on demand.

Damper Actuator
Damper Actuator can be provided to modulate the dampers of the AHUs.
21

DOUBLE SKIN AHUs SCREWLESS

VFD
Variable frequency drive can be provided with AHU, which helps in maintaining varying air flow by changing the
frequency and thereby Rpm of the motor to maintain the desired conditions. HVAC VFD with inbuilt basic controls
can also be provided.

UV emitter
UV emitter is used to improve the indoor Air Quality.
It can be mounted on the coil and hence does not require any extra space to mount.

Activated carbon filter


Activated carbon filter is used to remove the odor from the Air and can be provided in our AHU.

Empty Section
Sections with different lengths are available to suit any specific requirement.

Base Channel
Entire unit is completely supported by a full-perimeter base rail channel. The base rail is constructed of
2mm thick galvanised sheet steel and has intermediate cross member for unit support.

Unit Assembly
Units are despatched ex-factory upto E-500 in Top and Bottom assembled condition, and above that in dismantled
condition. The assembly of units will be carried out at site.

Factory Test
Each coil is factory tested and checked for leaks at 325 Psig (pneumatic) under water.
Performance Standards are:
In accordance to
Fans

- AMCA 210

Coils

- ARI 410

Motors - IS-325
Filter

- BS-6540 / ASHRAE 52 - 76

Note: E-Family AHU details can be obtained through E-Family AHU Selection Software.

22

USER'S MANUAL

YDW / YDX Coils: Nomenclature


1. YDW Water Cooling Coils:
YDW

12

24

94

Water Cooling Coil


Fins per Inch, 12 FPI
Fin Material A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H: Horizontal
Circuiting (Tubes per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand, R: Right, L: Left
Finned Length (FL), 26 to 114
L: Loose
Note: Field to specify (a) Circuits1/2" Copper) C. D; (b) Hand-off connection: LHS, RHS (viewing from air entering side)
Coil Specifications : OD Copper tube of thickness 0.41 mm with 0.14mm Aluminium fins.
Coils are OD Copper tube of thickness 0.5 mm with 0.15mm Aluminium fins are available as an option.

23

DOUBLE SKIN AHUs SCREWLESS

2. YDX Direct Cooling Coils:


YDX

12

24

94

0156

40

Direct Exp.
Fins per Inch, 12 FPI
Fin Material, A: Aluminium
Rows Deep (RD), 2, 4, 6, 8
Air Flow, H : Horizontal
Circuiting (Tubes per Circuit), B=4, C=6, D=8
Tubes High (TH), 12 to 48
Hand, R: Right, L: Left
Finned Length (FL), 26 to 114
L: Loose
Total Coil Load in MBH,
1 MBH = 1000 BTU/HR
Suction Temp., Deg. F
Tubes per Circuit, B=4, C=6, D=8
No. of Circuits
Note: Field to specify (a) Tube per circuit; (b) Hand-off connection: LHS, RHS.
Coil Specifications: OD Copper Tube of thickness 0.41mm with 0.14mm Aluminium fins.
Coils of OD Copper Tube of thickness 0.5mm with 0.15mm Aluminium fins are available as an option.

24

12

USER'S MANUAL

Transportation Storage
General
This manual is a complete guide for the Installation, Operation and Maintenance of Blue Star's Double Skin Air
Handling Units.
Proper installation, operation and maintenance are essential to optimise use of the AHU. The services of a qualified
technician from a reputed service company must therefore be employed through a suitable contract to install the
AHU.

Transportation & Handling


The Air Handling Units are inspected prior to despatch to ensure that the coil fins, casing panels, exteriors, fan
scroll and impeller are in good condition, cross-checked against items ordered, then packed and carefully loaded.

Material Receipt
Carefully inspect all material immediately upon delivery. If any damage is noticed, note the same and inform Factory
by telephone, fax or email within one week of receiving the material. Also fill up the Field Feedback Card which
accompanies the despatch documents and forward to Factory.

Storage
1. Protect the units from dust and dirt.
2. Do not store internal parts such as fans, motors, cooling coils, etc., in the open. If external parts are stored
in the open, ensure that they are well protected against the weather.
3. Do not place sections on top of each another.
4. Do not walk or place weight on top of the units.
5. Do not lean any materials on the units that can damage them, such as panels, aluminum profiles or other
external components.
6. Do not store any kind of materials inside sections.
7. Keep the units away from all passageways.
8. Protect protruding parts, coil connection, damper shafts, etc.
9. Place wooden wedges between the units and the ground.
10. Motors must not be stored in damp areas.
11. Filters must be left within packing cartons until ready for installation.
12. Protect fans from debris and dust.

25

DOUBLE SKIN AHUs SCREWLESS

Rigging Instruction
Proper rigging and handling of the equipment is mandatory during unloading and leading the AHU into position.
Care must be taken to keep the unit upright during rigging. Avoid unnecessary jarring or rough handling.
Proper hoisting straps should be used when rigging (nylon flat rope). It is also mandatory that an experienced
and reliable rigger be selected to handle unloading and final placement of the equipment. The rigger must be
advised that the unit contains internal components that require to be kept in an upright position. Care must be
exercised to avoid twisting of the equipment.

When the equipment is installed in its position, check the following:


1. Check all choke seams and air seals (below fan, motor etc.).
2. Check all door latches and re-adjust if necessary to maintain a good tight seal.
3. Fill up the Field Commissioning Report which accompanies the despatch documents and forward to Factory
upon commissioning of the AHU.

26

USER'S MANUAL

Packing List 25mm STANDARD-SKD Condition


CFM :
AHU Model

AHU Tag No.

Fan Model

Discharge Location

Coil Connection

SP : 50

630 CM

AHU Overall Dimensions (W * H * L) :


ICO No.

Batch Quantity

Sr.
No.

Item Description

1
U.M.

CASE
No.

SIZE

Q/S

Puf Panels
FAN + COIL SECTION
1
4

TOP /BOTTOM ASSEMBLY


Panel TOP (CUTOUT)

No.

4 -A

Panel TOP

No.

4 -B

Panel TOP

No.

Panel BOT

No.

5 - A

Panel BOT

No.

6 - B

Aluminum Extrusion Screwless - Length

No.

Aluminum Extrusion Screwless - Width

No.

Aluminum Extrusion Screwless B Type - Width

No.

8 - A

Aluminum Wedge

No.

8 - B

Aluminum Wedge

No.

8 - C

Aluminum Wedge

No.

8 - E

Aluminum Wedge

No.

19

Blower Sssly

19 - A

Spring isolator chanel

No.

19 - B

C - Fabrication

No.

19 - C

Motor mount

No.

19 - D

M - 12 Nut plate - 1

No.

19 - E

M - 12 Nut plate - 2

No.

20

CASE - 1
(Assembled
in Top / Bottom
Assembly)

Base Assly

20 - A

Base length - RH

No.

20 - B

Base length - LH

No.

20 - C

Base Width

No.

27

DOUBLE SKIN AHUs SCREWLESS

Sr.
No.

Item Description

U.M.

20 - D

Base Center

No.

20 - E

Base Corner

No.

25

Drain Pan

No.

22

Discharge flange Assly (Welded)

22 - A

CASE
No.

Discharge flange No.

17

Antivibrant Flexible Canvas Connection

No.

21

Coil Support No.

33

Motor Base Plate (50mm S.P)

No.

34

Spring Isolators - Fan Side Mounting

No.

35

Spring Isolators - Near to Motor

Set.

36

Spring Isolators - Away From Motor

No.

Back, LH and RH panels

Case 2

Panel LH - DOORNo.

27

Hinges ( Assembled with Door)

No.

37

BLUE STAR Logo (FIXED ON DOOR PANEL)

No.

1 - A

Panel LH

No.

1 - B

Panel LH

No.

Panel BACK

No.

2 - A

Panel BACK

No.

Panel RH

No.

3 - A

Panel RH

No.

3 - B

Panel RH

No.

6 - A

Aluminum Extrusion Screwless - Height

No.

7 - A

Aluminum Extrusion Screwless B Type - Height

No.

8 - A

Aluminum Wedge

No.

8 - B

Aluminum Wedge

No.

8 - C

Aluminum Wedge

No.

8 - D

Aluminum Wedge

No.

8 - F

Aluminum Wedge

No.

Loose Items
9

Blower

No.

12 - A

Blower Pulley (50mm S.P)

No.

10 - A

Coil

No.

Rubber Bush / Washer For Coil Header fixed on header.

Set.

11 - A

Motor (50mm S.P)

No.

13 - A

Motor Pulley (50mm S.P)

No.

42

28

case 3

case 4
case 4

case 5
case 5

SIZE

Q/S

USER'S MANUAL

Sr.
No.

Item Description

U.M.

CASE
No.

15

Damper : SA

No.

case 6

16

Pre Filter :

No.

case 7

16 - A

Pre Filter :

No.

SIZE

Q/S

Fabrication List
18

case 8

Filter frame Assly (Welded)


size

23

Coil Frame Assly

23 - A

Coil frame - TOP

No.

23 - B

Coil frame - LH

No.

23 - C

Coil frame - RH

No.

23 - D

Coil frame - BOT

No.

24

case 9

Spool Assly

24 - A

No.

24 - B

No.

Hardwares
26

Plastic Corner

No.

28

Handle

No.

29

Marine Light

No.

30

Limit Switch

No.

31

Hardware Set.

Set.

38

Door Switch Bracket.

No.

39

PTTJoint (25mm Standard) (FIXED WITH EXTRUSION)

No.

Belt (50mm S.P) - in hardware box

No.

40

Stickers

Set.

41

Rubber Bush / Washer For Cable Entry

Set.

14 - A

case 10

29

DOUBLE SKIN AHUs SCREWLESS

Packing List 25mm STANDARD-CKD Condition


AHU Model

AHU Tag No.

Fan Model

Discharge Location

Coil Connection

CFM

SP : 50

FDA

1000 CM
UPBLAST

AHU Overall Dimensions (W * H * L) :


ICO No.

Batch Quantity

Sr.
No.

Item Description

U.M.

Puf Panels
FAN + COIL SECTION
1

Panel LH

No.

Panel LH - DOOR

No.

Panel BACK

No.

2 - A

Panel BACK

No.

Panel RH

No.

Panel TOP

No.

4 -A

Panel TOP (CUTOUT)

No.

4 -B

Panel TOP (CUTOUT)

No.

Panel BOT

No.

1 - A

Aluminium Extrusions

30

Aluminum Extrusion Screwless - Width

No.

6 - A

Aluminum Extrusion Screwless - Height

No.

6 - B

Aluminum Extrusion Screwless - Length

No.

Aluminum Extrusion Screwless B' Type - Width

No.

7 - A

Aluminum Extrusion Screwless B' Type - Width

No.

7 - B

Aluminum Extrusion Screwless B' Type - Width

No.

7 - C

Aluminum Extrusion Screwless B' Type - Height

No.

8 - A

Aluminum Wedge

No.

8 - B

Aluminum Wedge

No.

8 - C

Aluminum Wedge

No.

8 - D

Aluminum Wedge

No.

8 - E

Aluminum Wedge

No.

8 - F

Aluminum Wedge

No.

8 - G

Aluminum Wedge

No.

Case
No.

Size

Q/S

USER'S MANUAL

Sr.
No.

Item Description

U.M.

Case
No.

Size

Q/S

Loose Items
9

Blower

No.

11

Coil

No.

11 - A

Coil

No.

12- A

Motor (50mm S.P)

No.

13 - A

Blower Pulley (50mm S.P)

No.

14 - A

Motor Pulley (50mm S.P)

No.

15 - A

Belt (50mm S.P)

No.

16

Damper : SA

No.

17

Pre Filter :

No.

17 - A

Pre Filter :

No.

Antivibrant Flexible Canvas Connection .

No.

18

Fabrication List
19

Filter frame Assly (Welded)

19 - A

Filter frame top

No.

19 - B

Filter frame side

No.

19 - C

Filter center support

No.

19 - D

Spring back down

No.

19 - E

Spring back up

No.

20

Blower Sssly

20 - A

Spring isolator chanel

No.

20 - B

C - Fabrication

No.

20 - C

Motor mount

No.

20 - D

M - 12 Nut plate-1

No.

20 - E

M - 12 Nut plate-2

No.

21

Base Assly

21 - A

Base length - RH

No.

21 - B

Base length - LH

No.

21 - C

Base Width

No.

21 - D

Base center

No.

21 - E

Base center - 2

No.

21 - F

Base Corner

No.

22

Coil Support

No.

23

Discharge flange Assly (Welded)

23 - A

Discharge flange

No.

31

DOUBLE SKIN AHUs SCREWLESS

Sr.
No.

Item Description

U.M.

24

Coil Frame Assly

24 - A

Coil frame - TOP

No.

24 - B

Coil frame - LH

No.

24 - C

Coil frame - RH

No.

24 - D

Coil frame - BOT

No.

25

Intermediate coil support

No.

26

Spool Assly

26 - A

No.

26 - B

No.

Drain Pan

No.

27

Hardwares
28

Plastic Corner

No.

29

Hinges (Assembled with Door)

No.

30

Handle

No.

31

Marine Light

No.

32

Limit Switch

No.

33

Hardware Set

Set.

35

Motor Base Plate (50mm S.P)

No.

36

Spring Isolators - Fan Side Mounting .

No.

37

Spring Isolators - Near to Motor

Set.

38

Spring Isolators - Away From Motor

No.

39

BLUE STAR Logo (FIXED ON DOOR PANEL)

No.

40

Door Switch Bracket No.

41

PTT Joint (25mm Standard)(FIXED WITH EXTRUSION)

42

Stickers

43

Rubber Bush / Washer For Cable Entry

Set.

44

Rubber Bush / Washer For Coil Header

Set.

34

Set.

(FIXED WITH COIL HEADER)

32

No.

Case
No.

Size

Q/S

USER'S MANUAL

Assembly Procedure of Double Skin


Horizontal Floor Mounted AHU
The Handling units models DHW - 035C to DHW - 500C are dispatched in SKD condition with Top and Bottom
panels assembled. The models DHW - 520C to DHW - 600 C are dispatched in CKD Condition.
A sample packing List for AHUs despatched in SKD and CKD Conditions are shown below:

Packing List 25mm STANDARD


(Screwless Construction)
AHU Model

AHU Tag No

DHW - 070
3750 CFM

Fan Model

FDA 355 CM

Air Flow

3750 CFM

Static Pressure

50 mm

RPM

1038

Discharge Location

Up blast (CCW 360)

AHU Overall Dimensions :

1370 (W) x 869 (H) x 1555 (L)

Customer Name

431-162-RVP-AGI-09

ICO No

431-162-RVP-AGI-09

Batch Quantity

Sr. No.

1
Item Description

U.M.

CASE No.

Size

Q / S

TOTAL QTY.

Puf Panels
1 .

Pre Flat Filter

2 .

Cooling Coil 6 Row

2 . 1

Panel : Left

460

784

2 . 2

Panel : Right

460

784

2 . 3

Panel : Top

460

1285

3 .

Fan Section

3 . 1

Panel : Top

460

1285

3 . 2

Panel : Top

460

1285

3 . 3

Panel : Bottom

460

1285

3 . 4

Panel : Bottom

460

1285

3 . 5

Panel : Back

620

784

3 . 6

Panel : Back

620

784

3 . 7

Panel : Access Door Right

460

784

3 . 8

Panel : Right

460

784

3 . 9

Panel : Left

460

784

3 . 10

Panel : Left

460

784

13

13

Total No. of Panels:

Aluminium Extrusions
Aluminium Extrusion A Type - Height

756

Aluminium Extrusion A Type - Width

1257

Aluminium Extrusion A Type - Length

1442

Aluminium Extrusion B Type

756.4

Aluminium Extrusion B Type

1257.4

Aluminium Extrusion B Type

624.4

Aluminium Extrusion B Type

181.4

Aluminium Wedges - TOP

463

Aluminium Wedges - TOP

1268

Aluminium Wedges - TOP

628.5

Aluminium Wedges - TOP

185.5

Aluminium Wedges - LEFT

463

Aluminium Wedges - LEFT

767

33

DOUBLE SKIN AHUs SCREWLESS

Aluminium Wedges - RIGHT

463

Aluminium Wedges - RIGHT

767

Aluminium Wedges - BOTTOM

463

Aluminium Wedges - BOTTOM

1268

Aluminium Wedges - BACK

623

Aluminium Wedges - BACK

767

Aluminium Wedges - For Frontal Flat Filter Frame(Height)

767

Aluminium Wedges - For Frontal Flat Filter Frame(Width)

1288

Aluminum Extrusion BAS-40C-Type Fan side

820

Aluminum Extrusion BAS-40C-Type Motor side

635

Sections
1

Pre Flat Filter


Prefilter: Box Type 48mm, Al Frame EU-3
(90% down to 10 micron)

Nos

610 (W) X 610 (H)

Frontal Flat Filter Frame

Set

1285(W) x 784(H)

Cooling Coil

Nos

YDW-12-A-6-H-C-22-L-40-L

Cooling Coil Frame

Nos

1299(W) x 798(H)

1240(W) x 415(L)

Cooling Coil 6 Row Section

Insulated Bottom Drain Pan (0.8 mm S.S-304) New Design

Nos

Drain Pan Deflector Plate

Nos

1235

Coil Support for Drain pan

Nos

1302

Rubber Bush / Washer For Coil Header

Nos

Fan Section
Fan

Nos

FDA 355CM

Motor

Nos

3HP, 4Pole

S.A. DAMPER ,GI(Standard)

Nos

452(W) x 452(H)

Blower Pulley

Nos

140mm PCD 30mm ID

Motor Pulley

Nos

100mm PCD 28mm ID

Belt (PACKED IN HARDWARE BOX)

Nos

1060 SPA (1)

Antivibrant flexible canvass connection

Nos

452(W)X452(L)

Motor Base Plate

Nos

3HP

T-Bolt

Nos

M10 X 20

12

12

Anti Vibration Isolater - As Shown in Fig. Point 1

Nos

RM 19. 100. B

Anti Vibration Isolater - As Shown in Fig. Point 2

Nos

RM 19. 100. R

Anti Vibration Isolater - As Shown in Fig. Point 3

Nos

RM 19. 100. R

Anti Vibration Isolater - As Shown in Fig. Point 4

Nos

RM 19. 100. B

Marine Light

Nos

Limit Switch

Nos

Polycarbonated Window

Nos

Spool for Vertical Discharge

Nos

Door Switch Bracket

Nos

Rubber Bush / Washer For Cable Entry

Nos

Handle For Access Door

Nos

Hinges

Nos

BLUE STAR Logo .(FIXED ON DOOR PANEL)

Sets

452(W) x 452(L) x 29(H)

Spring Isolater Channel

Set

1301 (L) x 85 (W)

S.A. Flange

Nos

452 (W) x 452 (H) x 75

Channels
Channel, Base. (Width)

Nos

1244

Channel, Base. (Length)

Nos

1429

Channel, Base. (Centre)

Nos

1344

1
8

Hardwares

34

Plastic Corner (for 25mm)

Nos

GI Base (25mm)

Nos

Gasket :
PTT Joint (25mm Standard )(FIXED WITH EXTRUSION)

Roll
Nos

4
18

4
18

Hardware Set

Set

Stickers

Set

20 * 3 mm

USER'S MANUAL

Assembly the AHU


Base Channel Assembly
1. Assemble GI base channel and corner piece with M6x25 mm long bolt and nut with one plain and one spring
washer on each side.
2. Overall dimensions of the base channel frame should be 30 mm less in length and width than the length and
width of the AHU / AHU Module.

Diagonally, the base frame should not be out by more than 1 mm.
All the base corners must be fitted from the inside.

35

DOUBLE SKIN AHUs SCREWLESS

Top Panel Assembly


1. Refer panel arrangement drawing. Assemble A type extrusion with glass filled nylon corners to form a top
frame required for fixing top panel - Drill the hole of 4.2mm & Rivet it with 7/16"x1/2" long rivet.
2. Place the B type extrusion on the specified distance mentioned in the panel arrangement Drawing.
3. Place the panel as shown in the drawing and maintain equal gap of 2 3mm between frame and panel all
around.
4. Insert the taper lock wedge in to the groove of A type and B type extrusion to lock the panel with extrusion.
5. Rivet the B type extrusion on A type extrusion by using 3/16" x 1/2" long rivet from inside.
6. If the fan orientation in the AHU is upblast, then fix the canvas connection flange on the cut out of the panel.
Reverse the top panel and fix the canvas connection from inside on connection flange.

Taper lock wedge should be inserted inside the groove of the extrusion until
its step touches to extrusion.

36

USER'S MANUAL

Bottom Panels Assembly


1. Refer panel arrangement drawing .Assemble A type extrusion with glass filled nylon corners to form a bottom
frame required for fixing bottom panel .
2. Place the B type extrusion on the specified distance mentioned in the panel arrangement Drawing.
3. Place the panel as shown in the drawing and maintain equal gap of 2 3 mm between frame and panel all
around.
4. Insert the taper lock wedge in to the groove of A type and B type extrusion to lock the panel with extrusion.
Empty space left is for drain pan.
5. Rivet B type extrusion on A type extrusion by using 3/16" x 1/2" long rivets.

Taper lock wedge should be inserted inside the groove of the extrusion until
its step touches to extrusion.

37

DOUBLE SKIN AHUs SCREWLESS

Base Channel & Bottom Frame Assembly


1. Position the base channel frame on the bottom frame. Maintain equal distance from all sides.
2. After positioning the frame, fix it with self drilling and tapping screws of size 4.2 mm x 25 mm long.
3. Use battery operated screw driver / power screw driver with Philips head for fixing self drilling and tapping
screws.
4. Turn the assembly upside down.

Normally bottom panel frame is 25mm more in size from all the side than
GI base channel assembly.

38

USER'S MANUAL

Drain Pan Assembly


1. Position the drain pan in the space left by panels in the bottom frame. Drain nipple should be on the header
side.
2. Place the drain pan in position and rivet it to the main frame with rivets of size 3/16" x 1/2" long.
3. Place the coil channel on the top of the drain pan and fix it on A type extrusion with the help self drilling /
tapping screws.
4. Apply some silicon gel at the periphery / edges of drain pan to avoid leakage.
Ensure that the drain nipple side of the drain pan should be on the side of
header of the coil.

39

DOUBLE SKIN AHUs SCREWLESS

Rubber Mount /Spring Isolator Assembly


1. Refer packing list for the type of rubber mount / spring isolator to be used and position it accordingly. Each
type of rubber mount or spring isolator is having different load carrying capacity.
2. Fix the rubber mount / spring isolator on the isolator channel .Place C type channel used for blower and
motor mounting on the top of spring Isolator as shown in the figure.
3. Level the spring Isolator height and tighten the nuts and bolts properly after providing spring and plain washer.
Fix the whole assembly to the bottom frame in the fan section.
Note: Rubber mounts are used for smaller model up to CDHW -120.

Positioning and fixing of rubber mount / spring isolator at the specified


location is very important since the load carrying capacity of the springs are
different.

40

USER'S MANUAL

Vertical Extrusions Assembly


1. Refer the packing list .Pick up vertical A type extrusion and confirm the dimension of the extrusion.
2. Insert it in the glass filled nylon corner of the bottom frame assembly.You may hammer the extrusion by plastic
or rubber hammer / mallet for the proper fitment.
3. Rivet the extrusion with corner from out side. Rivet size is 3/16" x 1/2" long.
Ensure the length of A type extrusion before fixing it, otherwise it may create
the problem for vertical panel fitment.

41

DOUBLE SKIN AHUs SCREWLESS

Top Frame Assembly


1. Place the top frame on top of the vertical extrusion. Confirm proper support to the top frame to avoid the breakage
of corner.
2. Rivet them together as explained earlier. Diagonally, the frame dimensions should not be out by more than
1 - 2 mm.
3. Overall dimension of the frame should be equal to the length, width and height of the AHU.

Verify the diagonal distance after placing the top panel assembly and then only
rivet the frame with corners.

42

USER'S MANUAL

Blower and Motor Assembly


1. Put the self adhesive gasket on the flange of canvas connector and fix it on the cut out panel with the help of
aluminium rivet of dia 3/16" * 25 mm long .
2. Place the blower on the mounting channel such that the fan opening matches with the cut out of the panel.
Put the self adhesive gasket on the periphery of the fan opening .Fix the other end of canvas connector on
the fan opening with the help of rivet of size 3/16" * 25 mm .In case of up blast orientation of fan, spool is to be
provided in between fan opening and canvas connector.
3. Mount the motor on the motor mounting base plate and fit it with the help of M8 /M10/M12 Bolt with bigger dia
of plain washer and spring washer as per the rating of the motor
4. Refer the packing list and mount pulley on fan and motor shaft Align both the pulleys with the help of straight
edge .Mount the v-belt , give the proper tension to v-belt with the help of tension gauge .Tight the motor mounting
base plate on channel.
5. Fix both the end of spring isolator channel on A type extrusion by using rivets of size 3/16" * 25 mm .
6. Level the height of all the springs by using spirit level and tight the lock nut of the spring Isolator.

Ensure proper tension of V belt by using belt tension gauge.


Ensure the leveling of spring isolator height.

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DOUBLE SKIN AHUs SCREWLESS

Coil Frame Assembly


1. Paste self adhesive foam gasket of size 20 x 3 mm on the end flanges of all four blank off of coil frame.
2. Paste self adhesive foam tape on top, bottom, and side plate of coil. Place the coil frame inside the unit and
position along the A or B type extrusion.
3. If the coil frame is placed on A type, then fix one side of coil frame on A type and other side on the sides of
coil with the help of self drill and tapping screw.
4. Screws for fixing top and bottom blank off should be fixed from air entry side. Ensure that the 175 mm side
coil frame blank off is fixed on the header side of the coil.
5. Once the coil is positioned properly, fixed the coil support on the A type with the help of self drill& tapping
screws of size 4.2 mm x 25 mm long.

Ensure the 175 mm width coil blank off is fixed on the header side of the coil.

44

USER'S MANUAL

Coil Assembly
1. Put the self adhesive foam gasket on the periphery of the coil flanges.
2. Position the coil on top of coil support channel which is fixed on the drain pan.
3. Header should be on 175 mm side of the coil frame. Coil inlet should be towards the blower side in the draw
through AHUs.
4. After positioning the coil, fix it with coil frame with the help of 4.2 x 25mm long self drilling and tapping
screws.

Coil inlet should be towards the blower side.

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DOUBLE SKIN AHUs SCREWLESS

Side panel assembly


1. Refer the panel arrangement drawing and place the B type extrusion at specified distance and fix it with rivet
of size 3/16" * 12 mm long from inside of AHU.
2. Place the panel as per drawing and maintain equal gap of 2 3mm between extrusion and panel all around.
Insert the taper lock wedge inside the groove of A and B type of extrusion.
3. Mark the position of the coil header on the panel and make the hole on the header panel. Roll on the rubber
collar on the coil header on the either side of the panel.

Do not forget to put the sleeve and rubber collar on the header.
Taper lock wedge should be inserted in side the groove of the extrusion until
its step touches to extrusion

46

USER'S MANUAL

Door assembly
1. Keep 4 -5 mm distance from B type extrusion or A type extrusion depend on which the hinge is going to be
fixed to the edge of access door for the smooth movement of the door.
2. One end of the hinge is fixed on Btype or A type extrusion and other end is fixed on the door.
3. Fix the handle in the hole provided on the door.Also fix the view port with gasket.
Holes to be drilled on A type and B type extrusion and fit the nut sert in it for
fixing auxiliary and access door. Ensure the Nut sert machine is available at
site.

47

DOUBLE SKIN AHUs SCREWLESS

Filter frame
1. Put the self adhesive foam gasket on the periphery of filter frame. Mount the filter frame on A/B type extrusion
and fix it by self drilling and tapping screw..
2. Mount the filters in the filter grid. Filters will get automatically locked because of the spring action of the supports
provided in the filter frame.

48

USER'S MANUAL

Sticker Position

49

DOUBLE SKIN AHUs SCREWLESS

Recommended Tools
Tools required in the Assembly of Screwless AHU

50

Hand Drill Machine (Reverse/Forward) 1 No.

Rivet Machine with Jig (Manual) 1 No.

Nut Sert Machine (Manual)

Spanner 10mm One side Fix & One Side ring. 2 Nos.

Spanner 13mm One side Fix & One Side ring. 2 Nos.

Spanner 16/17mm Fix 2 Nos.

Spanner 19mm One side Fix & One Side ring. 2 Nos.

Spanner 24/25 mm Fix 2 Nos.

Adjustable Spanner 1 No. (Maximum Opening 40mm)

Ratchet Spanner set with socket 10mm, 13mm, 15mm, 17mm, 19mm, and 24mm.

Allen key set 1 No. of Inch and 1 No. of mm.

Screwdriver (Flat type 4 Inch and 8 Inch. Length)

Screwdriver (Star type 6 Inch. Length)

Tester 1 No.

Knife 1 No. (Small)

Pliers 1 No.

Hacksaw (frame with Blade)

Measuring tape 5m

Silicon RTV Sealant 1 No.

Plastic Hammer 1.5 Inch. - 1 No.

Rubber Mallet 4 Inch 1No.

Metal Hammer 250 g 1 No.

Spirit level 1 No.

Chisel 3 Nos.

Screw Bit for 4.2mm Dia, 25mm length Screw 5 No.

Screw bit Holder 150mm, 75 mm For 4.2mm Dia, 25mm length Screw

M6 Bolt Socket of Drill Machine 1No.

Hole Saw cutter and Arbor 25mm, 40mm, 60mm, 75mm, 100mm 1No Each.

Drill bit 5mm 10 Nos.

Drill Bit 6 mm 2 Nos.

Drill Bit 10 mm 2 Nos.

Drill bit 12 mm 2 Nos.

C Clamp 6" 4 Nos.

Carpenters Vice 12 Feet long 1Nos.

Try Square 1 No. 6 Inch long.

Belt Tension Gauge

Vacuum Cleaner 1 No.

USER'S MANUAL

Electrical Information

Connect the power supply in accordance with local regulations. Earth all equipment at each section.

All wiring must confirm to IS and IE rules and possible local codes.

The power characteristics, voltage, phase and frequency are stamped on the name plate of the motor.

Whenever possible, electrical conduit/cable should be run to the unit from the bottom of the side panel/skid.

If junction box is provided, electrical cable connection made to the junction boxes on units must be made on
the bottom of the box. Installation must comply with code requirements. The installation should be made
watertight.
All exposed electricals MUST be checked for tight fastening prior to actual
startup. A poor connection can cause overheating and component failure
through inadequate current handling capacity.

A motor connection diagram is affixed on the inside of the motor terminal box cover. Be sure that extra cable
length is made available at the motor to permit fan belt adjustment.

All fan motors are three phase; totally enclosed fan cooled (TEFC) types with squirrel cage rotors.

The fan motors for Ceiling Suspended direct driven types are with single phase.

Standard motors have radial flow fan allowing fully reversible rotation. The motors are dynamically balanced.
Bearings are greased for life with considerable grease reserve.

Terminate the cable for DOL or Star/Delta as the case may be.

Check the cable size with respect to motor rating from the approved electrical single line drawing.

Complete both the cable termination and required earthing.

The AHU starter panel should be close to the AHU. Otherwise provide an isolator switch (disconnect) or on/
off push button station near the AHU.

The marine light inside will need a single phase 230V, 50 Hz AC supply. Provide an MCB in the AHU panel.

The limit switch (for fan access door) should be wired in the control panel of the AHU starter.

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DOUBLE SKIN AHUs SCREWLESS

Cooling Coil Installation


Coil Hand Selection
Coil hand connections (LHS or RHS) should depend on space availability for maintanance. Check the exact inlet
and outlet connection of the pipes to the coils. Water enters from the inlet nozzle at the bottom and exits at the
top. The water inlet should be at the air-leaving side.

General

Consult the job specifications and approved drawings for specific piping requirements, coil connection sizes
and location. The unit must be levelled to ensure proper venting and draining of coils. The piping arrangement
must be for a balanced flow in multiple coil installations.

The coil will meet performance ratings only if the air velocity is uniform over the face of the coil. High air velocity
spots on the coil may cause the carry-over of moisture from the coil. Low air velocity areas of the coil will not
deliver published rating. The duct connection must be designed to provide for uniform flow of air across the
face of the coil. In case of ducted return air, the entering duct must have a smooth transition from any high
velocity effects.

The heating coil will normally be for reheating. It must be located after the cooling coil in the direction of the air
flow.

Support all connecting piping independent of the coils. Provide swing joints or, preferably flexible fittings in all
piping connections, particularly adjacent to heating coils, to absorb expansion and contraction strains. Rigid
piping connection can cause coil damage.

The coils supply and return pipe connections are labelled. When connecting the piping to coil header; make
the connection only tight enough to prevent leaks. Excessive tightening may cause damage to the header.

52

USER'S MANUAL

Water Coils Drainable Water

Connect the water inlet to the bottom of the cooling


coil header on the air-leaving side of the coil and
the water outlet to the top of the header at the airentering side of the coil to achieve counter flow of
water and air.
Positive coil freeze protection must be used in
installations where any part of the coil is subjected
to temperature of 0 o C or lower. This may be
accomplished by using a suitable antifreeze
solution. If the coil is not in use, it is recommended
that the coil be completely drained and the inside
of the tubes blown dry with compressed air. Other
means of protection such as the full constant flow
of water can be used.

Direct Expansion (DX) Coils


Each coil must be installed with suction header towards the air-entering face of the coil and with the suction
connection at the lower end. The orientation of the refrigerant distributor is not critical but the distributor tubes
should not be pinched or bent in a non-uniform configuration. These coils are despatched from the factory with
Dry Air Pressure of 7-15 psig.
An individual expansion device must be provided for each coil at the field.
Thermostatic expansion valves are to be equipped with external equaliser connection that are field connected
to the suction lines. The valve should be sized in accordance with manufacturer's recommendations, allowing
approximately 35 psig pressure drop through the coil and distributor at full load. Do not oversize the valve. Follow
the manufacturer's instruction on the location of the thermostatic bulb. Proper expansion valve operation is
necessary in order to realise the rated coil capacity.
When a DX coil is operated with suction temperature below 00C, a build up of frost will occur on the finned surface.
It is, therefore, not recommended to use DX coils for airconditioning below freezing temperature. If the full load
operating point for the coil is selected at a safe temperature, a system analysis is required to check for the lowest
probable suction temperature at light load conditions. Suction pressure controlled hot gas by-pass valves are
available from various control manufacturers to maintain an adequate minimum suction temperature.

Air Velocity through Coils


The air velocity across the chilled water coil and direct expansion coils should be generally 2.54 m/sec. However
it must not exceed 2.8 m/s to prevent water carry-over. Air velocity, which is too low, will result in a low load situation
on the cooling coil, which will effect compressor operation. Air flow (m3/s) and air velocity (m/s) can be adjusted
by changing the fan/motor pulley sizes or by adjusting the fan outlet damper.

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DOUBLE SKIN AHUs SCREWLESS

Condensate Drain Piping


The majority of cooling coils are located in the units so that the supply air is drawn through them. This results in
condensate being subjected to negative pressure. Unless some means of pressure equalisation is provided in
the condensate drain, the air rushing back through the drain pipe will cause the condensate to build up in the
drain pan. As the unit continues operation, the accumulated water will be carried with the air stream. A trap should
be installed to prevent this condensate water build up. On initial startup, it may be necessary to fill the trap manually
or, after the unit has operated for some time, to allow for a small unit to fill the trap automatically.

Drain Pan
Drain pan

G.I. Elbow

IN NO RUN CONDITION

NORMAL RUNNING CONDITION


TRAP

G.I. Elbow
DIFFERENTIAL

Drain Pan

G.I. Elbow

CONDITION WHEN AN START

TOTAL HEAD

Condensate Drain Trap and Line Installation


Install a trapped condensate drain line at unit drain connection.
For Draw Through applications, the trap dimension must be at least 1/2 inch greater than negative static pressure
in the unit drain pan area. To determine trap dimension, first determine the negative static pressure in the unit.
Always assume the worst condition, such as dirty filter in the return air circuit to the fan.
Example:
Negative Static Pressure

- 0.5" - 0.5"

Minimum of 1/2"

- 0.5" - 0.5"

Drain pipe size

- 1.25" - 1.0"

Trap

- 2.25" - 2.0"

For Blow Through units, the same practice is followed, but the drain leaving the drain pipe should not be above
the bottom of the drain nipple.
Provide adequate foundation height to accommodate trap.
Do not connect the AHU drain trap directly to any plumbing line. Contamination of air may take place. Condensate
drain pipe should be insulated to avoid sweating.

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USER'S MANUAL

Air System

Duct Connection Guidelines


All discharge air duct connections to the unit may be directly connected only for Horizontal AHUs, Vertical
AHUs with multiple blower. All other AHUs, terminate the ducting through canvas connections. Duct turn and
transition must be made carefully to hold frictional losses to a minimum. Avoid short turns. Duct elbows should
contain splitters or turning vanes. Duct work connected to the fan discharge must run in a straight length for at
least two equivalent outlet diameters and should not be reduced in cross sectional area. A duct turn should be in
the same direction as the fan rotation.
Installations of the elbow and other abrupt flow area changes
directly at the fan outlet will cause system losses. These
losses must be taken into account during the design phase
and must be added to any field measurements.

Sound and Vibration Transmission


All Air Handling Units generate some sound and vibration that may or may not require special treatment of the air
handling duct/rooms. The noise generated by the air handling unit is dependent on the speed of the fan, the amount
of air, the type of fan and the static efficiency of the fan. In applications where sound and vibration transmission
may be objectionable, good acoustical engineering practices must be incorporated in the system design. It is
better to locate the AHU away from noise sensitive areas. The supply ducts should be internally lined. Silencers
may also be installed.
On units with return fans, it is especially important to consider
the effects of sound transmission into the conditioned space.

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DOUBLE SKIN AHUs SCREWLESS

Pre-Start Up
Adjustment and Checks
Belt and Sheaves
Improper sheave alignment and belt tension are frequent causes of excessive vibration as well as shortened
belt and bearing life. The Vee Belts used are SPA, SPB , SPZ, SPC as required. Please check the above provided.

Air Filters
All filters are shipped loose. It is mandatory that filters be in place in the filter frames of each unit before putting
the unit into operation to protect the coil and keep them clean.
When the unit is first started, dirt and debris from the building/duct is likely to be sucked in. Hence, place a muslin
cloth in front of the filters to prevent them from getting choked.

Air Flow Control Dampers


Dampers are intended for use with individual controllers, actuators or manually.

Start-up checks

Have transportation restraints been removed?

Check supply voltage, in all three phases and voltage unbalance

Check fan's wheel and drive sheaves

Set screw tight and check drive alignment

Check bearing for alignment and locking collars for tightness

Rotate wheels and motors to ensure freedom of movement

Are drain traps of correct shape and size?

Check to see that proper air filters are installed

Check the AHU is connected to the duct

Check the fan outlet damper is operational

Operational Checks

Momentarily start the fan motor and ensure correct rotation

Check belt tightness

Check RPM of, and amperes drawn by, supply fan motor

Check cabinet for air leakage

Check cabinet for possible water leaks

Latch/Tighten all panels

56

USER'S MANUAL

Safety Checks
Be sure all door latches (locks) are secured before starting unit.
Fans are dynamically balanced at fan manufacturer's works. However, there are certain operating speeds at which
the natural frequency of the rotating member is attuned to the natural frequency of certain panels which are the
part of the enclosure. These vibrations can tend to reinforce each other in such a way that excessive vibration
can be encountered under certain conditions. It is difficult to predetermine such condition, as it is affected by
mounting arrangement, the various modules used in the make up of assembly and the duct connections and
operating condition.
Under no condition should the unit be allowed to operate when excessive unit vibration is apparent. Permanent
damage may result due to this.
After 24 hours of satisfactory operation, shut down the equipment and check all foundation bolts, shaft bearing
and drive set screws and tighten wherever required.
If the above check reveals no apparent discrepancies and vibrations still persist, the speed of the unit should be
lowered by approximately 10% to determine if a natural frequency is causing the vibration. If the unit contains
water coils, they must be filled when this check is made.
Trained personnel should be available at the time of start up
of the Air Handling Units.

Motor
Do not operate fan motors in overload amperage condition.
Do not energise the motor if earthing is not completed.

Before mounting the V belts, it is preferable to run the motor at no load condition and check the no load current
and verify the direction of rotation.
It is not desirable to run the AHU for long periods without providing filters and connecting to duct work since the
fan will draw more current and the coil will also choke with dust.
Motor amperage should be checked again after the connecting duct is installed and an air flow check made on
the air distribution system. Only in those cases where the airflow at the outlet is insufficient to meet specification
should the blower speed be changed. However, when the speed is changed, check the adequacy of fan motor as
BHP increases by an order of the cube of the ratio of increase in RPM. Also check the adequacy of switch gear.

Belt
Belt should be checked for correct tension at start up and should be checked again after 24 hours of operation.
On multiple belt adjustable pulleys, the pitch depth should be checked to ensure identical belt travel, power transfer
and wear. An adjustable motor base is provided for belt adjustment. Figure on page 43 illustrates the belt tension
guage.
Do not operate fan motor until lubrication has been checked
and drive adjusted.
If the motor operates at incorrect voltage or on 2 phases, the motor may draw full load current at no load condition.

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DOUBLE SKIN AHUs SCREWLESS

Operation
Pre-Operation Check

Lock out electrical power to prevent accidental fan operation. Check the inside of the unit and duct work to
make sure that no loose nuts, bolts, trash, sheet metal parts etc. have been left behind, which may be sucked
into fan and result in permanent damage. At the same time, check to make certain that air filters have been
placed in the filter section, with fill pieces in place.

Recheck the tightness of the mounting hardware, set screws and locking collars on the bearing, and motor
mount adjustment nuts.

Rotate the fan shaft by hand to make sure that it is free and no obstruction has been caused during
transportation.

Check the bearing for proper lubrication by referring to the bearing lubrication instructions. At the same time
if the bearing contains locking collars, make sure that the locking collars have been locked in the direction of
the fan rotation.
All transportation hold nuts must be removed completely
to permit fan to ride freely on the isolators.

Recheck the fan and motor sheave alighment with a straight edge and belt tension for proper values.

Refer to the fan motor manufacturers instructions attached to the fan motor and check each item for compliance
prior to start-up.

Operational Check

After the pre-operational check, apply power to the motor for a short interval to observe that the fan is rotating
in right direction as indicated by arrow on the side of the blower scroll. Check the fan speed with tachometer.

Check the current drawn by motor with an ammeter. Correct rotation and speed if required. Do not exceed
maximum speed or amperage.

Stop the machine immediately if any unusual sound or


vibration occurs and recheck all items.

If the vibration continues, the belt should be removed from the drive and motor allowed to run unloaded to determine
if the motor shaft is possibly bent, if there are defective motor bearing or if the motor is unbalanced or the pulley
is out.

58

USER'S MANUAL

Maintenance
General
A programmed regular maintenance will avert possible costly and unexpected downtime. It is the responsibility
of the owner to provide the necessary maintenance for the Air Handling Units and coils. If a system failure occurs
due to improper maintenance during warranty period, BSL will not be liable for the cost incurred to bring the unit
back to satisfactory operation.
Removable access door fitted with viewport has been provided on all units for necessary maintenance and to
provide access to various components which in time may require replacement.

Note:

Filter used during building construction must be replaced with clean filter prior to the occupancy

of the building.

Periodic Maintenance
Every Month
Check the cleanliness of the filters and clean as required.
Examine the damper and operating linkages to ensure that each is free and operating smoothly.

Every Three to Six Months

Add grease (Servogem 3) to the fan shaft bearing as indicated by the schedule from the bearing manufacturer
which has been attached to the unit. The exact period between lubrication is related to the rotational speed
and the atmosphere surrounding the bearing.

For normal operating conditions, the grease should confirm to NL GL. Grade 2 consistency. It is important that
the grease be free of chemical impurities, moisture, and dust, metal particles or abrasives. The bearing should
be lubricated while the shaft is turning. The grease should be pumped in slowly until a slight bead forms around
the outside of the seals. This bead, in addition to an indication of the adequate lubrication, provides protection
against the entry of the foreign matter. Excessive grease should be removed from the internal bearing to prevent
it from being picked up by the fan. Dirt will collect on the fan and eventually cause imbalance, resulting in
vibration and component failure.

If the grease fitting must be changed, it is important to see that the locking pin is in place when the fitting is
replaced. If an adapter or grease fitting of improper size and length is used, the locking pin may be either too
tight or loose and can affect the alignment and re lubrication of the bearing.

Adjust the belt tension if necessary. Never use a belt dressing on the belt. If belt slips in spite of proper tension,
use a good grade of belt cleaner to clean the belt. Use the motor base plate for adjusting the belt tension.
Never use excessive tension as this could result in damaging
the bearing.

59

DOUBLE SKIN AHUs SCREWLESS

When it is necessary to replace one belt in a given set, the entire set of belts must be replaced by a matched
set. Check the lubrication instruction for the installed motor and lubricate the motor as indicated.

Inspect the condensate drain trap and ensure that it is clear and free.

Check the bearing locking collars or set screw for tightness. Inspect the coils for cleanliness. If necessary,
hose the coils down with a low pressure water hose or low pressure air.
Never use hot water or steam on refrigerant coils as
dangerous pressure can build up within the coil.

Every Year

Clean the fan and inspect the drain pan for sludge and foreign material. Clean if required.

Observe the operation of all dampers and make any necessary adjustment in linkages and blade orientation
for proper operation.

Inspect the coil for cleanliness. if necessary, hose the coil down with low-pressure water hose or low-pressure
air.

60

USER'S MANUAL

Winterising System Components


Freeze Protection
All Chilled Water coils can be damaged during freezing weather. Precautionary measures must be taken to prevent
freezing such as:

For all year operation and shut-down such as power failure, night shut-down and weekend shut-down, the
controls must be installed so that the valves will go to the full heat position, and all fresh air dampers go to the
full closed position. The water circulation pump must be kept circulating water through the coil and/or auxiliary
heat must be maintained inside the cabinet.

Drain each coil and related piping such as traps and make sure that all the areas are drained.

After draining, flush coils with antifreeze solution such as ethylene glycol. A solution of 50% ethylene glycol
and 50% water will protect freezing below zero at sea level.

Winterising Drain Traps


During the winter months when the cooling system is turned off and the unit is exposed to freezing condition, an
antifreeze solution should be poured in the condensate drain trap to prevent freezing and possible damage. The
condense drain trap may also be drained.

Dampers
Dampers, operators, control and linkages must be checked prior to applying power to the operators, making
sure nothing will obstruct the operation of the damper. Do not overdrive damper operator as this may cause damage
to the damper.

61

DOUBLE SKIN AHUs SCREWLESS

Removal or Reinstallation
of Components
Blower
Follow these steps to remove the blower from casing:

Remove the belts from the drive

Loosen the retaining bolts of the blower

Fix the clamp below the blower base as shown in figure below

Remove the blower retaining bolt completely

Remove blower

If a new blower is installed, make sure that the spring selection matches the blower and motor. The blower should
also be properly balanced.

Coil Replacement
Access to the coil is obtained by removing the connecting piping from the coil and the panels at each end of the
coil.
For direct expansion coils, it is necessary that the refrigerant be pumped down into the condenser and contained.
Under no circumstances should the piping joints in DX coils
be heated for unseating while refrigerant is within the coil.
Dangerous pressure, gases and fire can result.

62

USER'S MANUAL

Belt Replacement
Always replace belts as a matched set. Used belts will always be longer because of stretching and belts should
never be installed singly on a multiple drive.
The adjusting nuts on the fan motor should be loosened and the belt placed in the sheaves. Never place the belts
on the sheaves by using a screwdriver to try each belt over the rim of the sheaves. Once the belts are in place,
the sheaves on the fan shaft and motor should be checked with a straight edge for alignment. Check the middle
groove of each sheave when multi groove pulleys are used.
Next, adjust the belt tension using the adjusting bolts on the motor mount. Use a recognized gauge such as one
shown in figure for adjusting the tension.
To determine the deflection force required, use the formula:
Deflection = Belt Span / 64

Do not over tighten the belt or the bearing may get damaged.
The best tension for a belt drive is the lowest tension at which
the belt will not slip under the highest required load.

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DOUBLE SKIN AHUs SCREWLESS

Installation
Double Skin Vertical Air Handling Units
These units are fully assembled at the factory, packed properly and despatched. Upon receipt at site, these units
are to be unloaded carefully as illustrated in this manual and lead carefully to the place of installation.
Vertical D S Air Handling Units, with single blower arrangement are not provided with canvass connection at the
factory. Canvass connections are provided within the unit at factory for units with multiple blowers.
Install these units at site on 25 mm thick ribbed rubber pads of size 150 mm X 150 mm (2 layers of 12 mm thick
each placed one on top of other with a GI sheet of same size in between) at four corners. Ensure that the units are
leveled properly.
The units with single blower outlet are to be connected through a fire retardant canvass connection to the ducting
at site. It is preferable to install a Volume Control Damper of opposed blade type at the blower outlet to adjust the
air quantity of the AHU. Units with multiple blower arrangement are not required to be provided with canvass
connection at site, whereas one Volume Control Damper is recommended to be provided in the ducting to adjust
the air quantity.

64

USER'S MANUAL

D S Ceiling-suspended
Air Handling Units
These units are fully assembled at the factory, packed
properly and despatched. Upon receipt at site, these
units are to be unloaded carefully as illustrated in this
manual and lead carefully to the place of installation.

Typical Ceiling suspension by fully threaded rods

These units are ceiling suspended with the help of 4


suspension rods. The anchor fasteners used for
suspending the units from the ceiling should be able to
withstand the weight of the unit. The Units can be
suspended from an M S structural work also.

Ensure that the corner pieces are provided at the bottom


of the vertical extrusion at all four corners as shown in
the following illustrations. These corner pieces are
shipped alongwith the units from the factory.

Bottom corners (supplied loose)

For critical and sensitive installations, where non


transmission of vibration is very important, special
suspension arrangement is to be incorporated while
suspending the units as shown.

Special isolator
(if required)

These units are not provided with any canvass


connection at the fan outlet from the factory. Hence fire
retarded canvass connection is to be provided at the
outlet of the unit prior to connecting to the ducting. It is
preferable to install a Volume Control Damper of
opposed blade type at the fan outlet to adjust the air
quantity.

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DOUBLE SKIN AHUs SCREWLESS

Troubleshooting
If your Air Handling Unit is not functioning properly, do check the following before
calling for service.

Trouble
Air flow is less

Cause

Remedy

Filter clogged

Clean filter.

Cooling coil clogged

Clean cooling coil.

Belt loose

Tighten the V belt.

Low Voltage

Ensure that correct


voltage is available.

Volume Control Damper


stuck or partially closed.

Check and adjust the


volume control damper.

RPM of fan less

Check the rpm with


design and change pulley
if required.

Static pressure high

System static pressure


has increased.
Check with design.

Air leaving temperature


of cooling coil high

Chilled water in temperature


high

Ensure that the design


water temperature is
available at cooling coil
inlet.

Less water flow

Check any clogged


water strainer and clean.
Check water balancing.
Check any valve stuck
in partially open
position.

Accumulation of water
in AHU

Water carry over

66

Cooling coil clogged

Clean the cooling coil.

Quantity of air flow is more

Adjust the flow rate by


volume control damper or
changing the pulleys.

U trap not provided

Provide U trap in the


condensate drain line of
adequate depth.

Drain line clogged

Clean the drain line.

Air quantity too high

Adjust the air quantity.

Face velocity of coil high

Measure the velocity and


adjust to the design
value.

USER'S MANUAL

Trouble
Noise and vibration

AHU motor trips

AHU not starting

Cause

Remedy

Unbalanced impeller

Check the static


balancing at site. If
required get the impeller
balanced dynamically.

Unbalanced pulleys

Balance the pulleys.

V Belt loose

Tighten the V belt.

Air quantity too high

Change the pulleys to


obtain required air
quantity.

Low voltage

Ensure that correct


voltage is available.

Air quantity too high

Adjust the air quantity.

Two AHUs working in parallel


and one AHU stopped

Close the discharge


damper of the AHU not
working.

Faulty overload

Check the overload


and replace.

Single phasing

Check all the phases


and replace burnt out
fuse.

Low voltage

Check and ensure that


correct voltage is
applied.

Single phasing

Check all the fuses


and take corrective
action.

67

DOUBLE SKIN AHUs SCREWLESS

Preventive Maintenance
SOP (Standard Operating Procedure) for Pre Filter Cleaning
Aim: Routine cleaning of prefilter
Standard followed: As per filter manufacturer.
Scope of work: To monitor and verify cleanin of prefilter
Percentage of cleaning required: 100%
Note: Before starting work check the house keeping in Pre filter mounting room. Every worker should be in proper
clothing & should wash the hands with soap water before starting the process.

Steps to be followed for Pre Filter cleaning:


Step - A
a. Check the house keeping in the prefilters mounting area
b. Remove the dust with proper tools
c. Transfer the filters to cleaning area
d. Avoid cleaning filters near to the Air Handling unit
e. Take out the filters from covers individually.
f. Use 1.5 to 2bar compreseed air to clean
g. Clean the filters from the outlet side
h. The distance from air nozzle to filters should be 6 inch.
i.

Starting from one corner move the nozzle all over the area.

j.

Cleaning to be done anywhere between 2-5 minutes depending on size of filter and area of filteration.

k. After cleaning filter medium remove dust on the frame by cloth dipped in IPO.
l.

Transfer the cleaned filters to clean polythene cover and shit it to safe place.

m. Shift the cleaned filters to mounting area


n. Clean the mounting frames totally, any dust e.t.c. are not acceptable on finished filter
o. Fix it with appropriate fastners.

Final Ovservation
Tighten the fastners for no leakage of air.

68

USER'S MANUAL

Spare Parts List / CDHW


AHU MODEL

V-BELT
CODE

DISCRIPTION

QTY/AHU

CDHW - 035

SPZ-750

750

SPZ (1)

CDHW - 040

SPZ-750

750

SPZ (1)

CDHW - 050

SPZ-1000

1000

SPZ (1)

CDHW - 070

SPZ-1000

1000

SPZ (1)

CDHW - 080

SPZ-1000

1000

SPZ (1)

CDHW - 100

SPZ-1120

1120

SPA (1)

CDHW - 110/120

SPZ-760

760

SPZ (1)

CDHW - 135

SPZ-950

950

SPZ (2)

CDHW - 150

SPZ-950

950

SPZ (2)

CDHW - 160

SPZ-950

950

SPZ (2)

CDHW - 175

SPZ-1160

1160

SPZ (2)

CDHW - 190

SPZ-1160

1160

SPZ (2)

CDHW - 200

SPZ-1120

1120

SPZ (2)

CDHW - 220

SPA-1220

1220

SPA (2)

CDHW - 230/240

SPA-1220

1220

SPA (2)

CDHW - 255

SPA-1320

1320

SPA (2)

CDHW - 265

SPA-1320

1320

SPA (2)

CDHW - 290

SPA-1450

1450

SPA (2)

SPA-1220

1220

SPA (2)

CDHW - 325

SPA-1650

1650

SPA (2)

CDHW - 340

SPA-1650

1750

SPA (2)

CDHW - 355/370/390

SPA-1950

1950

SPA (2)

CDHW - 410

SPB-2000

2000

SPB (2)

CDHW - 430/445

SPB-2000

2000

SPB (2)

CDHW - 470/490/500

SPB-2150

2150

SPB (2)

CDHW - 520/540

SPB-2120

2120

SPB (2)

CDHW - 570

SPB-2120

2120

SPB (2)

CDHW - 600

SPB-2120

2120

SPB (2)

CDHW - 300

CDHW - 455

69

DOUBLE SKIN AHUs SCREWLESS

AHU MODEL
CODE

DISCRIPTION

QTY/AHU

CDHW - 035

AHF610617

Prefilter-EU3-AL-BOX-610W610H

CDHW - 040

AHF610617

Prefilter-EU3-AL-BOX-610W610H

CDHW - 050

AHF610617

Prefilter-EU3-AL-BOX-610W610H

CDHW - 070

AHF610617

Prefilter-EU3-AL-BOX-610W610H

CDHW - 080

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF305309

Prefilter-EU3-AL-BOX-305W305H

CDHW - 135

AHF610617

Prefilter-EU3-AL-BOX-610W610H

CDHW - 150

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF305614

Prefilter EU3-AL-BOX-305W610H

CDHW - 190

AHF610617

Prefilter-EU3-AL-BOX-610W610H

CDHW - 200

AHF610617

Prefilter-EU3-AL-BOX-610W610H

CDHW - 220

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

CDHW - 100

CDHW - 110/120

CDHW - 160

CDHW - 175

CDHW - 230/240

CDHW - 255

CDHW - 265

CDHW - 290

70

FILTER

USER'S MANUAL

AHU MODEL

FILTER
CODE

DISCRIPTION

QTY/AHU

AHF305309

Prefilter-EU3-AL-BOX-305W305H

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF305309

Prefilter-EU3-AL-BOX-305W305H

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF610309

Prefilter-EU3-AL-BOX-610W305H

CDHW - 355/370/390

AHF610617

Prefilter-EU3-AL-BOX-610W610H

12

CDHW - 410

AHF610617

Prefilter-EU3-AL-BOX-610W610H

12

CDHW - 430/445

AHF610617

Prefilter-EU3-AL-BOX-610W610H

12

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

12

AHF305614

Prefilter-EU3-AL-BOX-305W610H

CDHW - 470/490/500

AHF610617

Prefilter-EU3-AL-BOX-610W610H

15

CDHW - 520/540

AHF610617

Prefilter-EU3-AL-BOX-610W610H

12

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF305309

Prefilter-EU3-AL-BOX-305W305H

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

15

AHF610309

Prefilter-EU3-AL-BOX-610W305H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

15

AHF610309

Prefilter-EU3-AL-BOX-610W305H

CDHW - 300

CDHW - 325

CDHW - 340

CDHW - 455

CDHW -5701

CDHW - 600

71

DOUBLE SKIN AHUs SCREWLESS

AHU MODEL
CODE

DISCRIPTION

QTY/AHU

AHI065000

Rubber Mount : RM.19B

AHI068000

Rubber Mount : RM.19Y

AHI065000

Rubber Mount : RM.19B

AHI068000

Rubber Mount : RM.19.Y

AHI062800

Rubber Mount : RM.19R

AHI065000

Rubber Mount : RM.19.B

AHI065000

Rubber Mount : RM.19B

AHI065000

Rubber Mount : RM.19B

AHI065000

Rubber Mount : RM.19B

AHI062800

Rubber Mount : RM.19R

CDHW - 100

AHI062800

Rubber Mount : RM.19R

CDHW - 110/120

AHI062800

Rubber Mount : RM.19R

CDHW - 135

AHI251000

Spring isolator : OS 25-100

HI256000

Spring Isolator : OS 25-60

AHI251000

Spring isolator : OS 25-100

AHI256000

Spring Isolator : OS 25-60

AHI251000

Spring isolator : OS 25-100

AHI256000

Spring Isolator : OS 25-60

AHI251000

Spring isolator : OS 25-100

AHI251600

Spring Isolator : OS 25-60

AHI251000

Spring isolator : OS 25-100

AHI251600

Spring Isolator : OS 25-60

AHI251000

Spring isolator : OS 25-100

AHI251600

Spring Isolator : OS 25-60

AHI251000

Spring isolator : OS 25-100

AHI251600

Spring Isolator : OS 25-60

AHI251000

Spring isolator : OS 25-100

AHI251600

Spring Isolator : OS 25-160

AHI251000

Spring isolator : OS 25-100

AHI251600

Spring Isolator : OS 25-160

AHI251600

Spring Isolator : OS 25-160

AHI252500

Spring Isolator : OS 25-250

AHI251000

Spring isolator : OS 25-100

CDHW - 035

CDHW - 040

CDHW - 050

CDHW - 070

CDHW - 080

CDHW - 150

CDHW - 160

CDHW - 175

CDHW - 190

CDHW - 200

CDHW - 220

CDHW - 230/240

CDHW - 255

CDHW - 265

72

RUBBER MOUNT / SPRING ISOLATOR

USER'S MANUAL

AHU MODEL

CDHW - 290

CDHW - 300

CDHW - 325

CDHW - 340

CDHW - 355/370/390

CDHW - 410

CDHW - 430/445

CDHW - 455

CDHW - 470/490/500

CDHW - 520/540

CDHW - 570

CDHW - 600

RUBBER MOUNT / SPRING ISOLATOR


CODE

DISCRIPTION

QTY/AHU

AHI251600

Spring Isolator : OS 25-160

AHI252500

Spring Isolator : OS 25-250

AHI251000

Spring isolator : OS 25-100

AHI251600

Spring Isolator : OS 25-160

AHI252500

Spring Isolator : OS 25-250

AHI251000

Spring isolator : OS 25-100

AHI251600

Spring Isolator : OS 25-160

AHI252500

Spring Isolator : OS 25-250

AHI252500

Spring Isolator : OS 25-250

AHI251600

Spring Isolator : OS 25-160

AHI252500

Spring Isolator : OS 25-250

AHI251600

Spring Isolator : OS 25-160

AHI252500

Spring Isolator : OS 25-250

AHI251600

Spring Isolator : OS 25-160

AHI253000

Spring Isolator : OS 25-250

AHI252000

Spring Isolator : OS 25-200

AHI253000

Spring Isolator : OS 25-300

AHI252000

Spring Isolator : OS 25-200

AHI253000

Spring Isolator : OS 25-300

AHI252000

Spring Isolator : OS 25-200

AHI254000

Spring Isolator : OS 25-400

AHI252000

Spring Isolator : OS 25-200

AHI254000

Spring Isolator : OS 25-400

AHI252000

Spring Isolator : OS 25-200

AHI254000

Spring Isolator : OS 25-400

AHI252000

Spring Isolator : OS 25-200

73

DOUBLE SKIN AHUs SCREWLESS

AHU MODEL

LIMIT SWITCH
CODE

DISCRIPTION

QTY/AHU

CDHW - 035

AHL001600

Limit Switch LSR Bohmen make

CDHW - 040

AHL001600

Limit Switch LSR Bohmen make

CDHW - 050

AHL001600

Limit Switch LSR Bohmen make

CDHW - 070

AHL001600

Limit Switch LSR Bohmen make

CDHW - 080

AHL001600

Limit Switch LSR Bohmen make

CDHW - 100

AHL001600

Limit Switch LSR Bohmen make

CDHW - 110/120

AHL001600

Limit Switch LSR Bohmen make

CDHW - 135

AHL001600

Limit Switch LSR Bohmen make

CDHW - 150

AHL001600

Limit Switch LSR Bohmen make

CDHW - 160

AHL001600

Limit Switch LSR Bohmen make

CDHW - 175

AHL001600

Limit Switch LSR Bohmen make

CDHW - 190

AHL001600

Limit Switch LSR Bohmen make

CDHW - 200

AHL001600

Limit Switch LSR Bohmen make

CDHW - 220

AHL001632

Limit Switch LSR Bohmen make

CDHW - 230/240

AHL001708

Limit Switch LSR Bohmen make

CDHW - 255

AHL001752

Limit Switch LSR Bohmen make

CDHW - 265

AHL001828

Limit Switch LSR Bohmen make

CDHW - 290

AHL001862

Limit Switch LSR Bohmen make

CDHW - 300

AHL001914

Limit Switch LSR Bohmen make

CDHW - 325

AHL001914

Limit Switch LSR Bohmen make

CDHW - 340

AHL001994

Limit Switch LSR Bohmen make

AHL002006

Limit Switch LSR Bohmen make

CDHW - 410

AHL002537

Limit Switch LSR Bohmen make

CDHW - 430/445

AHL002071

Limit Switch LSR Bohmen make

CDHW - 455

AHL002120

Limit Switch LSR Bohmen make

CDHW - 470/490/500

AHL002071

Limit Switch LSR Bohmen make

CDHW - 520/540

AHL002071

Limit Switch LSR Bohmen make

AHL002084

Limit Switch LSR Bohmen make

AHL002149

Limit Switch LSR Bohmen make

CDHW - 355/370/390

CDHW - 570
CDHW - 600

74

USER'S MANUAL

AHU MODEL

CANVAS
CODE

DISCRIPTION

QTY/AHU

CDHW - 035

HACAZ1010

flexible canvas conn-10-10

CDHW - 040

HACAZ1209

flexible canvas conn-12-09

CDHW - 050

HACAZ1212

flexible canvas conn-12-12

CDHW - 070

HACAZ1515

flexible canvas conn-15-15

CDHW - 080

HACAZ1813

flexible canvas conn-18-13

CDHW - 100

HACAZ1818

flexible canvas conn-18-18

CDHW - 110/120

HACAZ0450

flexible canvas conn-450

CDHW - 135

HACAZ0500

flexible canvas conn-500

CDHW - 150

HACAZ0500

flexible canvas conn-500

CDHW - 160

HACAZ0500

flexible canvas conn-500

CDHW - 175

HACAZ0560

flexible canvas conn-560

CDHW - 190

HACAZ0560

flexible canvas conn-560

CDHW - 200

HACAZ0560

flexible canvas conn-560

CDHW - 220

HACAZ0630

flexible canvas conn-630

CDHW - 230/240

HACAZ0630

flexible canvas conn-630

CDHW - 255

HACAZ0630

flexible canvas conn-630

CDHW - 265

HACAZ0710

flexible canvas conn-710

CDHW - 290

HACAZ0710

flexible canvas conn-710

CDHW - 300

HACAZ0710

flexible canvas conn-710

CDHW - 325

HACAZ0710

flexible canvas conn-710

CDHW - 340

HACAZ0800

flexible canvas conn-800

CDHW - 355/370/390

HACAZ0800

flexible canvas conn-800

CDHW - 410

HACAZ0900

flexible canvas conn-900

CDHW - 430/445

HACAZ0900

flexible canvas conn-900

CDHW - 455

HACAZ0900

flexible canvas conn-900

CDHW - 470/490/500

HACAZ0900

flexible canvas conn-900

CDHW - 520/540

HACAZ1000

flexible canvas conn-1000

CDHW - 570

HACAZ1000

flexible canvas conn-1000

CDHW - 600

HACAZ1000

flexible canvas conn-1000

75

DOUBLE SKIN AHUs SCREWLESS

Spare Parts List / SDVW


AHU MODEL

SDVW - 035

SDVW - 050

SDVW - 070

SDVW - 100

SDVW - 140

SDVW - 170

SDVW - 200

SDVW - 250

SDVW - 270

SDVW - 300

76

V - BELT
ITEM CODE

DISCRIPTION

QTY/AHU

SPA-800

Belt ( 40 mm SP ),800-SPA-1

SPA-800

Belt (32mm SP), 800-SPA-1

SPA-800

Belt (40mm SP), 800-SPA-1

SPA-800

Belt (32mm SP), 800-SPA-1

SPA-1220

Belt (40mm SP),1220-SPA-1

SPA-1060

Belt (32mm SP),1060-SPA-1

SPA-1060

Belt (40mm SP),1060-SPA-1

SPA-1000

Belt (32mm SP),1000-SPA-1

SPA-1060

Belt (40 mm SP),1060-SPA-1

SPA-1000

Belt (32 mm SP),1000-SPA-1

SPA-1120

Belt (40mm SP), 1120-SPA-1

SPA-1000

Belt (32mm SP), 1000-SPA-1

SPA-1250

Belt (40mm SP),1250-SPA-1

SPA-1000

Belt (32mm SP),1000-SPA-1

SPA-1400

Belt ( 40 mm SP ),1400-SPA-1

SPA-1120

Belt ( 32 mm SP ),1120-SPA-1

USER'S MANUAL

FILTER
AHU MODEL

ITEM CODE

DESCRIPTION

QTY/AHU

SDVW - 035

AHF400502

Prefilter-EU3-AL(400X500)

SDVW - 050

AHF600507

Prefilter-EU3-AL(600X500)

SDVW - 070

AHF400603

Prefilter-EU3-AL(400X600)

AHF500603

Prefilter-EU3-AL(500X600)

SDVW - 100

AHF500407

Prefilter-EU3-AL(500X400)

SDVW - 140

AHF500407

Prefilter-EU3-AL(500X400)

SDVW - 170

AHF600407

Prefilter-EU3-AL(600X400)

SDVW - 200

AHF500407

Prefilter-EU3-AL(500X400)

AHF600407

Prefilter-EU3-AL(600X400)

AHF500507

Prefilter-EU3-AL(500X500)

AHF600507

Prefilter-EU3-AL(600X500)

SDVW - 250

SDVW - 270
SDVW - 300

RUBBER MOUNT/ SPRING ISOLATOR


AHU MODEL

ITEM CODE

DESCRIPTION

QTY/AHU

SDVW - 035

AHI065000

RM 19 . 100 B

AHI068000

RM 19 . 100 . Y

AHI062800

RM 19 . 100 R

AHI065000

RM 19 . 100 . B

AHI062800

RM 19 . 100 R

AHI065000

RM 19 . 100 . B

AHI062800

RM 19 . 100 R

AHI065000

RM 19 . 100 . B

AHI062800

RM 19 . 100 R

4]

AHI065000

RM 19 . 100 . B

AHI062800

RM 19 . 100 R

AHI065000

RM 19 . 100 . B

SDVW - 200

AHI062800

RM 19 . 100 R

SDVW - 250

AHI062800

RM 19 . 100 R

SDVW - 050

SDVW - 070

SDVW - 100

SDVW - 140

SDVW - 170

SDVW - 270
SDVW - 300

77

DOUBLE SKIN AHUs SCREWLESS

CANVAS CONN.
AHU MODEL

DESCRIPTION

QTY/AHU

SDVW - 035

NR

SDVW - 050

NR

SDVW - 070

NR

SDVW - 100

NR

SDVW - 140

HACAZ1515

flexible canvas KAT 15X15

SDVW - 170

HACAZ1813

flexible canvas KAT 18X13

SDVW - 200

HACAZ1818

flexible canvas KAT 18X18

SDVW - 250

HACAZ0450

flexible canvas-450

SDVW - 270
SDVW - 300

78

ITEM CODE

USER'S MANUAL

Spare Parts List / DCW


AHU MODEL

V-BELT
ITEM CODE

DESCRIPTION

QTY

SDCW4017B

SPA-850

850

SPA(1)

SDCW4027B

SPA-850

850

SPA(1)

SDCW4035B

SPA-850

850

SPA(1)

SDCW4042B

SPA-850

850

SPA(1)

SDCW4050B

SPA-850

850

SPA(1)

SDCW4060B

SPA-950

950

SPA(1)

SDCW4070B

SPA-850

850

SPA(1)

SDCW4078B

SPA-850

850

SPA(1)

SDCW4085B

SPA-950

950

SPA(1)

SDCW4093B

SPA-900

900

SPA(1)

SDCW4100B

SPA-900

900

SPA(1)

SPA-800

800

SPA(2)

SDCW4110B

SPA-1060

1060

SPA(1)

SDCW4118B

SPA-1060

1060

SPA(2)

SDCW4127B

SPA-1090

1090

SPA(2)

SDCW4135B

SPA-1090

1090

SPA(2)

SDCW4035D

NR

SDCW4050D

NR

SDCW4070D

NR

79

DOUBLE SKIN AHUs SCREWLESS

AHU MODEL
CODE

DISCRIPTION

QTY

SDCW4017B

AHF600407

Prefilter-EU3-AL-BOX-600W400H

SDCW4027B

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4035B

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4042B

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4050B

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4060B

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4070B

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4078B

AHF400502

Prefilter-EU3-AL-BOX-400W500H

AHF500507

Prefilter-EU3-AL-BOX-500W500H

AHF400502

Prefilter-EU3-AL-BOX-400W500H

AHF500507

Prefilter-EU3-AL-BOX-500W500H

SDCW4093B

AHF610617

Prefilter-EU3-AL-BOX-610W610H

SDCW4100B

AHF400603

Prefilter-EU3-AL-BOX-400W600H

AHF500603

Prefilter-EU3-AL-BOX-500W600H

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

AHF305614

Prefilter-EU3-AL-BOX-305W610H

AHF610617

Prefilter-EU3-AL-BOX-610W610H

SDCW4127B

AHF610617

Prefilter-EU3-AL-BOX-610W610H

SDCW4135B

AHF610617

Prefilter-EU3-AL-BOX-610W610H

SDCW4035D

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4050D

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4070D

AHF500407

Prefilter-EU3-AL-BOX-500W400H

SDCW4085B

SDCW4110B

SDCW4118B

80

FILTER

USER'S MANUAL

AHU MODEL

RUBBERMOUNT/SPRING ISO/PAD
CODE

DISCRIPTION

QTY

SDCW4017B

AHI070000

Rubber Pad

SDCW4027B

AHI070000

Rubber Pad

SDCW4035B

AHI070000

Rubber Pad

SDCW4042B

AHI070000

Rubber Pad

SDCW4050B

AHI070000

Rubber Pad

SDCW4060B

AHI070000

Rubber Pad

SDCW4070B

AHI070000

Rubber Pad

SDCW4078B

AHI070000

Rubber Pad

SDCW4085B

AHI070000

Rubber Pad

SDCW4093B

AHI070000

Rubber Pad

SDCW4100B

AHI070000

Rubber Pad

SDCW4110B

AHI070000

Rubber Pad

SDCW4118B

AHI070000

Rubber Pad

SDCW4127B

AHI070000

Rubber Pad

SDCW4135B

AHI070000

Rubber Pad

SDCW4035D

AHI070000

Rubber Pad

SDCW4050D

AHI070000

Rubber Pad

SDCW4070D

AHI070000

Rubber Pad

81

DOUBLE SKIN AHUs SCREWLESS

Field Feedback Card


Product:

Air Handing Unit

AHU Model:
Unit Sr. No. :
Customer Name :

Location :

Date :
Observation
Quality of Packing

Comments

Details of Defects

OK / Damaged

Receipt of Documents
-

Packing List

Yes / No

Panel Arrangement Drawing

Yes / No

Condition of Parts :
-

Aluminium Extrusion

OK / Damaged

Puf Panels

OK / Damaged

Hardware

OK / Damaged

Drain Pan

OK / Damaged

Fabricated Frames

OK / Damaged

Coil

OK / Damaged

Blower

OK / Damaged

Motor

OK / Damaged

Drive Set

OK / Damaged

Filters

OK / Damaged

Dampers

OK / Damaged

Remarks :

Checked by
For Factory Use :

82

Date of Receipt :

Comments :

- Action By :

USER'S MANUAL

Field Commissioning Report


To be filled on Com

Product:

Air Handing Unit

AHU Model:
Unit Sr. No. :
Customer Name :

Location :

Date :
Observation

Comments

Details of Defects

Performance Checks :
-

Assembly

OK /

Installation

OK /

Commissioning

OK /

Air Quantity ( CMH / CFM )

Static Pressure ( Pa / mm )

Blower ( RPM )

Motor Current ( Amps )

Noise Level ( dba )

Vibration

OK /

Air balancing, If done at site

Yes / No

Change in Pulley Size at site

Yes / No

Others, if any

Commissioning Date

Commissioning By

Remarks :

Note: Warranty will be valid only after receipt of this form at Factory.
For Factory Use :
-

Date of Receipt :

Comments :

- Action By :

83

DOUBLE SKIN AHUs SCREWLESS

WARRANTY CLAIM FORM FOR AHU


(A copy of this form is to be filled in case of AHU failure, by BSL Engineer)
Location (City) ______________________________

Date ______________

AHU MODEL NO:

AHU Serial No

Date of despatch
Warranty commencing date
Application in which the equipment used

Date of Commissioning
Warranty expiry date

Customers Name and Address

Dealers Name and Address

Starting problem
Noise at starting

 Yes
 Yes
 Yes

 No
 No
 No

Noise while running


If there is noise, indicate the type of noise from the list __________________________________________
Blower Fan: Unbalanced, Vibration, Rubbing, Shaft bent.
Electric Motor: Jammed, Bearings failed, Internal noise, Burnt out. (Check voltage, current, insulation resistance).

Voltage at each phase

 Yes
 Yes
 Yes

Voltage at each phase to phase


Insulation resistance (Megger test)

 No
_______________ Mohms

Any leakage in the coil

 Yes
 Yes
 Yes
 Yes
 Yes
 Yes
 Yes

Electrical problem
Three phase balanced

Filters clogged
Filters worn out
Condition of V Belts
Belt tension correct
Alignment checked
All bolts of Fan/Motor tightened

 No
 No
 No
 Yes

 No
 No
 No
 No
 No
 No
 No

Signature & Seal of Customer

Signature & Seal of BSL Engineer

Date: ________________

Date: ________________
(For factory use)

Claim Settled 
Credit Advice No._________________
Claim Rejected 
Reasons for rejection _________________________________________________________________
Settlement authorised by: _____________________
Date: _____________________

84

USER'S MANUAL

Warranty
Blue Star AHUs carry a warranty for a period of 12 months from the date of commissioning
or 15 months from the date of delivery, whichever is earlier, unless stated otherwise in
the contract of sales.
Warranty coverage shall be applicable from the date of receipt of Field Commissioning
Report (see page 75) at Blue Star Bharuch Factory.
While filing a claim for Warranty repairs, please allow our representative to fill in the
Warranty Claim Form (see page 76) and send it to Factory for speedy Warranty repairs.

Terms of Warranty
Blue Star extends a comprehensive Warranty on its systems, which entitles the customer to
the following:
1. Repair/reconditioning, by BSL/BSL Dealer, through whom the machine has been purchased,
of any part of the equipment found defective within 12 months from the date of commissioning
or 15 months from the date of despatch whichever is earlier.
2. The warranty is valid only if:
2.1 Installation and commissioning is taken care of by BSL/their authorised persons.
2.2 The equipment is operated as per the Companys operating instructions.
3. The above said warranty does not cover the following:
3.1 Consumables such as V belts, air filters etc.
3.2 Deterioration or failure of equipment due to corrosive atmosphere.
4. This warranty is not valid if any repair and/or modifications are carried out by the customer
himself or his representative without written concurrence from Blue Star Limited.
5. The guarantee extended herein is in lieu of all implied conditions/warranties under the law
and is confined to the repairs or replacements of defective parts and does not cover any
consequential or resulting liability damage or loss arising from such defect. Furthermore,
the guarantee in no case, shall extend to the payment or any monetary consideration
whatsoever of the replacement or return of the AHU as a whole.
6. Any repair/replacement shall not extend the overall warranty period as specified above.
7. The cost of transportation of material and of persons beyond Municipal jurisdiction shall be
borne by the customer.
8. This warranty may be read in conjunction with any other warranty on the installation as a
whole, if the AHU is supplied as part of a project.

85

DOUBLE SKIN AHUs SCREWLESS

Service Centres
EAST

SOUTH

WEST

BHUBANESHWAR
3A, Satya Nagar,
2nd Floor,
Bhubaneswar 751 007.
Tel: (0674) 2508270 / 2508239

BANGALORE
Ozone Manay Technology Park
Sy. No. 56/18 & 55/9
Hongasandra Village
Begur Hobli,
Garvebhavipalya
Bangalore 560 068
Phone : 41854000

AHMEDABAD
2nd Floor, Shivalik - II,
Near Shivranjani Cross Roads,
132 Feet Ring Road, Satellite,
Ahmedabad - 380015.
Tel: (079) 40224000

GUWAHATI
New Star Freeze Building
2nd Floor,
Opp. Kunjalata Bibah Bhawan,
G. S. Road,
Guwahati 781 005.
Tel: (0361) 2340619 /
2340620
KOLKATA
7, Hare Street
Kolkata 700 001.
Tel: (033) 22134200 /
22106609

NORTH
CHANDIGARH
SCO 1, Madhya Marg, Sector 26,
Chandigarh 160 019.
Tel: (0172) 2790482 /
5004000
JAIPUR
A-19, Main Sahakar Path,
Near Sahakar Bhawan,
Jaipur - 302 001.
Tel: (0141) 5124898 / 2744033
LUCKNOW
177/4, Faizabad Road,
Lucknow 226 007.
Tel: (0522) 4034000
NEW DELHI
E-44/12 Okhla Ind. Area
Phase II, Ohkla
New Delhi 110 020.
Tel: (011) 41494200 / 000

86

CHENNAI
104, Garuda Building,
Cathedral Road,
Chennai 600 086.
Tel: (044) 42444200
28116707- 8
KOCHI
2nd Floor, Millennium Plaza,
MKK Nair Road,
Alinchuvadu Junction,
Kochi 682 024.
Tel: (0484) 4499000
SECUNDERABAD
207, Sikh Road
Bantia Estates
Secunderabad 500 003.
Tel: (040) 27847553 /
27842057-58 / 27815469
TRIVANDRUM
T.C. IX/1490
Chandrika,
Sasthamangalam
Trivandrum 695 010.
Tel: (0471) 2720025 / 2720065
VISAKHAPATNAM
D. No. 49-24-65/1,
Near Sankarmattam Road,
Madhura Nagar,
Visakhapatnam 530 016.
Tel: (0891) 2748405 /
2748433

BHOPAL
Star Arcade, 2nd Floor
Plot No.165A & 166, Zone-I
Maharana Pratap Nagar
Bhopal 462 011.
Tel: (0755) 2553378 /
4273378 / 79
GOA
1st Floor,
Buddhaseth Apartments,
Tonca, Caranzalem,
Goa 403 002.
Tel: (0832) 2461671 / 2462087
MUMBAI
Blue Star House
9A, Ghatkopar Link Road
Saki Naka, Mumbai 400 072.
Tel: (022) 66684200 / 66684000
NAGPUR
219, Bajaj Nagar, 1st Floor,
South Ambazari Road,
Nagpur 440 010.
Tel: (0712) 2229244 / 2249000
PUNE
201/A, Nityanand Complex
1st Floor, 247/A
Bund Garden Road
Pune 411 011.
Tel: (020) 41044000 / 26113031
26127230 / 26122307
VADODARA
Ramakrishna Chambers
7th Floor, Productivity Road
Alkapuri, Vadodara 390 005.
Tel: (0265) 2338561 / 2332021 / 22

USER'S MANUAL

For any
assistance,
CALL:
Blue Star Service:
Ph: ............................................................
Cell: ..........................................................

Blue Star Dealer:


Ph: ............................................................
Cell: ..........................................................

Blue Star Regional Manager:


Ph: ............................................................
Fax: ..........................................................

Blue Stars/Dealers engineer to fill


above details before handing over
this Manual to customer.

87